Trans Digest 12

7/26/2019 Trans Digest 12

1/6841TE 5L40-E/5L50-E NVG 247 RE4F03/4B

VOLUME 31, NO. 6 FEBRUARY 2012

The Automotive Powertrain Industry Journal

D I G E S T


2/68

SmartShell

F R O M S O N N A X

The Sonnax SmartShellis the rst and only kit

to prevent damage to the 4L60 shell as well as the

captured bearing in the rear planetary assembly.

Visitwww.sonnax.com for more on the SmartShell

or contact your transmission distributor today!2011 Sonnax Industries, Inc.

Fix 4L60 series sun gear shell problems

with BRAINS, not just brawn.

PERFORMANCE

Sonnax Part No.

77749-02K

Patent Pending

OE Sun Shell

Thrust load passes from

shell through sun gear,

then overloads the small

captured planetary bearing.

SmartShell

Thrust load passes directly to

the carrier from the shell through

the large bearing & race, bypassing

the small captured planetary bearing.

The Sonnax SmartShell

kit includes an improved,

strengthened shell, bearing

assembly & custom race.

Sonnax is an

Employee-Owned Company

SmartShell

Reinforced shell withstands

torque load. OE plastic thrust

washer replaced by large

bearing which supports

shell to withstand

thrust load.

OE Sun ShellIn addition to torque load

damage, thrust load exes

& breaks shell at the bend.

Color Key

ShellRace

Sun Gear

CarrierKeyBearings

Thrust Load Path

Circle No. 15 on Reader Card


3/68

PRINTED IN THE U.S.A.

Transmission Digest(ISSN 0277-8300) is published monthly by M D Publications, Inc., 3057 E. Cairo, P.O. Box 2210, Springfield, MO 65801-2210. Advertising inquiries are welcome, by mail or telephone,(417) 866-3917; Fax (417) 866-2781; [email protected]. Advertising rates furnished upon request. Advertiser and agency agree to indemnify and protect the publisher from unauthorized use of anypersons name, photograph, statement or copyrighted material. Copies available by subscription: One year (12 issues) United States and U.S. possessions $39; Canada $48; all other countries via IPA $81 inU.S. funds only. Single copy price $4.75 plus shipping for current or back issues (as available) except the Annual Buyers Guide which is published as the March issue.Copyright 2012 by M D Publications, Inc. All rights reserved. Advertisements and Signed articles do not necessarily reflect the opinions of Transmission Digestor its management. Editorial contributionswelcome, but return of manuscripts, models or other artwork not guaranteed unless accompanied by a self-addressed stamped envelope. Information contained in Transmission Digesthas been carefully

compiled from industry sources known for their reliability, but M D Publications does not guarantee its accuracy. Other M D Publications: Undercar Digest, Tech/Talk, and Short Line. M D Show Division:TRANSMISSION/UNDERCAR EXPO 2012, March 29-31, Dallas. Periodicals Postage paid at Springfield, Missouri, and additional entry offices.POSTMASTER: Please send address changes to Transmission Digest, P.O. Box 2236, Springfield, MO 65801-2236.

VOLUME 31, NO. 6 FEBRUARY 2012

D I G E S T

News & Previews

From the Publisher .............2

The Top 10 Tools &Products Winners ............30

Showpower Exhibitors .......46

Information Source ...........49

Powertrain Products....55-57

Industry News Highlights...58

Marketplace................59-64

Index to Advertisers..........64

Labor of a LifetimeKeith McCulloch, founder of KeithsTransmission & Sales Inc. in Kansas

City, Kan., learned the value of hardwork as a boy and is still at it as henears his 84th birthday.

Page 4

Technical

Technically Speaking: . . . .8The cause of a solenoid-

performance code in a

41TE can be elusive.

Shift Pointers . . . . . . . . .22A loose-fitting solenoid wire

can cause a harsh 1-2 upshiftin a Nissan RE4F03/4B.

Tech to Tech . . . . . . . . . .24A retired patrol car

transformed into a drag

racer is put to the test.

R&R Tech . . . . . . . . . . . .28An alternator noise can

masquerade as a

transmission problem.

Up to Standards . . . . . . .34

Diagnosing and servicing theNVG 247 transfer case

Body of Evidence . . . . . . .36Identifying the 5L40-E and

5L50-E transmissions and

their valve bodies

Torque ConverterTech Tips . . . . . . . . . . . .44

Solving bearing failure in

Honda torque converters

Business

Its Your Business . . . . . .42

Dont let your customerscontrol your business.

On The Cover

Showpower 2012You can find technical andmanagement information to helpyou thrive during these tougheconomic times along with thelatest tools, equipment, productsand services in Dallas.

Page 14

February 2012 1

CERTIFIED


4/68

2 Transmission Digest

From the

Publisher

By Bobby Mace

Se Habla:

Executive

Carol Langsford

President

Michelle Dickemann

Vice President

Bobby Mace

Publisher

[email protected]

Editorial

Gary Sifford

Editor

[email protected]

Wayne Colonna

Technical Editor

Terry Greenhut

Business Editor

Mike Weinberg

Contributing Editor

Art Department

Jay Young

Creative Director

Lonnie Bolding

Art Administrator

Circulation

Dudley Brown

Circulation Manager

Mike Turner

[email protected]

Advertising Sales

Mike Anderson

[email protected]

Accounting/Credit

Muriel Lincoln

Credit Manager

Donna Blackburn

Showpower 2012Hyatt Regency Dallas

March 29-31

Bob Jacobsmeyer

Exhibit Manager

[email protected]

Founder

Les Langsford,

19281993

TRANSMISSION DIGEST

M D Publications, Inc.

(417) 866-3917

As we busily prepare for theupcoming ShowpowerExpo it seems to me that

we havent given sufficient at-tention to one of the seminarsessions. Jose Garcia from ATSGcombines his abilities to communicate

effectively in Spanish with complete technical competency. Ithink were very lucky to have his session, presented inSpanish as part of the Texas expo.

Saturday, March 31, provides a rare opportunity for re-pair-shop owners in the Metroplex area and beyond to en-roll those technicians who are more comfortable withSpanish than with English. Joses session will rely on pro-viding diagnostic and rebuilding knowledge on a selectionof subjects that have been most on the minds of those callingthe ATSG hotline recently.

Showpower and Transmission Digest are proud to joinATSG in providing this unique opportunity for an areawhere many of the top builders and technicians speakSpanish as a native tongue. More information detailingShowpower Expo begins on page 14; registration forms areadjacent to page 32.

Congratulations to Joe Horn of Joes HamiltonTransmission in Hamilton, N.J. Joe was one of many whovoted in the Top 10 Products and Tools contests. A randomdrawing awards Joe a complimentary passport to attend theShowpower Expo. Top 10 contest winners for 2012 are rec-ognized beginning on page 30 of this issue. TD

This month in

4L60/4L60-E/4L65-E/4L70-E: Correcting poor 1-2 and 2-3 shift quality

4L60/4L60-E/4L65-E/4L70-E: Third-gear starts

GM 4L60-E: Code P0741 stored, cruise control inoperative

5L40-E: Line-pressure instability

6L40/50/80, GM6: Delayed, slipping reverse; slide 2-3

6L40/50/80/90, GM6, GA6L45R: Solenoid performance codes

Transmission

A u t o m o t i v e T e c h n i c a l N e w s l e t t e r s


5/68

*See our website for full warranty details

3YEAR/ 100,000MILENATIONWIDEWARRANTY* Visit our website for full warranty details



6/68

Keith, who will be 84 in April,has operated Keiths Transmission& Sales Inc. in Kansas City, Kan.,with his wife, Janette, and son Raysince 1967. The Sales part of thename is a carryover from when thecompany sold recreational vehicles.

When he left the family farm,Keith went to work for a filling sta-tion and stayed there until he wasalmost 18 and then enlisted in theU.S. Air Force to serve as a motor-pool mechanic. After his dischargein 1949, he got a job as a mechanicat a Ford dealership in Kansas City,Kan. He spent the next 21 yearsthere, completing Ford Motor Co.scourse on servicing and repairingFords two-speed Ford-O-Matic

transmission in the early 1950s.During that time Keith also hadstarted a small shop of his own todo car repairs and continued withthat after leaving the dealership.

About 1967, Keith started train-ing Ray as a mechanic and theyworked together at the new busi-ness. While Keith was working forTWA at night, Ray would work inthe shop, and Keith would run theshop in the daytime.

We bought this place in 1972,

Growing up on a farm innorthern Utah where hisfamily raised dairy cattle

and sugar beets, Keith McCullochlearned to work hard and put inlong days. At age 14 he left thefarm for a job in the city, and al-

most 70 years later hes still puttingin full days rebuilding automatictransmissions.


Founder Keith McCulloch rebuilds alot of the rear-wheel-drive units. Heenjoys woodworking in his time

away from the shop.

Janette said of the building thathouses the shop. The formerowner, a welder, had built thebuilding that same year and found

that he didnt need that muchspace, so he offered to sell it to theMcCullochs.

From 1969 through 1991, wesold recreational vehicles in addi-tion to doing transmissions,Janette said. We liked that busi-ness too, but it just wasnt going tobe a paying business like the trans-missions.

In addition to three lifts insidethe shop, Keiths has two outside.

As long as its not too cold andtheres not snow on the ground, weuse them to check vehicles, and onelift is for heavy vehicles like minimotor homes and things like that,or something thats too tall to comein the door.

Because people remember thatwe were in that business at onetime, we see a few small motorhomes that we just do things likethe transmission or change the

This certificate acknowledges Keithscompletion of Ford Motor Co.scourse on service and repair of theFord-O-Matic transmission in 1952.

continues page 6


7/68



8/68


Rebuilder and diagnostician ScottMartin has worked at Keiths for 15years.

transmission fluid for people whoknow us and like to bring themhere.

Kansas City, Kan., is just acrossthe Missouri River from KansasCity, Mo., so the shop draws cus-tomers from both states. Onewholesale customer is a general-re-pair shop about 60 miles away, Raysaid. There are about 14 general-repair garages that bring theirtransmissions or the whole vehiclesto us. Some of them will bring thetrannies only in, some will bringthe whole vehicles in.

Working on high-performanceand antique transmissions is aniche business that Ray enjoys.

We do a fair amount of transmis-sions for street-rodders at the carshows. We see more of the olderstuff with those guys. Ive beendoing it for years.

He says he knows of only oneother shop in the area that will re-build antique transmissions. We

dont see a lot, but we still see cast-iron Powerglides and some of thecast-iron Cruise-O-Matics.

GM 700-R4 and 200-4R and FordAOD units are still popular withstreet-rodders in the area, he said.

Other than a few rear-wheel-drive units, Keiths doesnt rebuildautomatic transmissions for inven-tory, Ray said. We build them asthey come in because of the elec-tronics and the ratios. If someonewants to preorder something wewill go ahead and put somethingtogether for them, but thats veryrare. Almost everybody just redoesthe originals. Like everybody,weve got a few of the basic rear-

wheel-drives on the shelf. As far asfront-wheel-drives we dont try topre-build any of those, because be-tween the differential ratios andthe sprocket ratios, the electronicschanging, theyre just hard tostock.

Keith rebuilds a lot of the rear-

wheel-drive units. Rebuilders ScottMartin and Kevin Reynolds handlefront-wheel-drive units, and Scottalso does some of the diagnosis.

Ray and Scott are ASE certifiedand are members of both ATSGand ATRA, and they attend techni-cal seminars every year to stay cur-rent.

The shops standard warrantyon rebuilt transmissions is 12months/12,000 miles, Ray said. Foran additional cost the customer canextend the coverage to as much asthree years or 100,000 miles. Theyhave that option, but in this area,most people dont want to spendthe extra money it costs.

Percentage-wise, one out of everyhundred might want the longerwarranty.

Because Keiths has been in busi-ness so long and is well known inthe area, he said, the only advertis-ing is a small ad in the yellowpages. This place is pretty muchall word of mouth.

The shop rebuilds 15-16 units inan average week, including thecarry-in units, Ray said. Three of

the garage customers always bringthe whole vehicle, and he prefersthat arrangement because it helpsto prevent installation problems.

The biggest deal nowadays isnot getting the cooling systemscleaned out properly, he pointedout. If they cant get them cleanedout and they dont have a scan toolto hook up to know whats goingon, thats a big downfall withcarry-in shops. So we prefer the

whole car if possible. TD

Lynetta Lawrence, Scott Martins

mother, works in the office.

Kevin Reynolds, rebuilder, has been

at the shop for eight years.

Richard Montgomery, an 11-yearemployee, is one of two R&Rtechnicians. Joshua Clair, offwork because of an injury and notpictured, has worked at the shopfor about a year.

Keiths wife, Janette, and son RayMcCulloch


9/68

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10/68

Without question, asidefrom P1776 (47), one ofthe most-common trou-

ble codes plaguingDodge/Chrysler vehicles is P0750(or 41), Low/Reverse SolenoidCircuit error, in 41TE-type trans-missions (see Shift Pointers,October 2008). This is purely anelectrical code and typically pointsto the solenoid, the wiring (whichincludes the connectors) from thesolenoid body to the TCM, or theTCM itself. In so many instanceson our technical hotline the causehas been a defective TCM. Whatbecomes very frustrating is out-of-the-box remanufactured TCMscoughing up the same code as soonas they are installed; makes youthink you missed something inyour previous diagnosis.

Just recently John Thorntonfrom Autotrain Inc. ran into anoth-er scenario that caused this code toset and was kind enough to share


Low/Reverse-Solenoid Circuit

Fault

Subject:

Solenoid performance code

Unit:

41TE

Vehicle Applications:

2007 Chrysler Sebring Coupe

Author:

Wayne Colonna, ATSGTransmission DigestTechnical Editor

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & R

Technically Speaking

TECHNICAL

TRAINING

2

3

1

Code P0750 (41)

continues page 10


11/68Circle No. 6 on Reader Card


12/68



it with me. Now, keep in mind thatall too often when this code popsup usually the first line of attack isto throw a solenoid body at it(sometimes this can be a literalact!). If that doesnt work thewiring might be replaced, followed

by a TCM.Admittedly, a good portion ofthe time the code is resolved byone of these three methods; that is,if you happen to get a good reman-ufactured TCM. Otherwise, thiscode will drive you crazy, and outof desperation you finally use ameter or scope to locate the prob-lem. After all, when everything hasbeen replaced and the status of thecode remains the same (a newZeppelin song), everything is stillup for grabs. Except in Johns case,which as you will see is a testi-mony to hooking up a scope firstto see whats going on, as some-times we get blindsided with pat-tern-failure repairs and end upthrowing parts at the car to seewhat works.

The vehicle was a 2007 ChryslerSebring Coupe (JS) 2.4L with a41TE sporting the P0750 code. Theunit had been replaced twice, and

what makes this particular vehicleof interest is that it has the GlobalPowertrain Engine Computer(GPEC) (Figure 1) instead of theold 60-way TCM. Could this meanthat GPECs as well as the previousNew Generation Controllers(NGC) 3 & 4 are cursed also?

After verifying the presence ofcode P0750 John attached his scopeto each of the four solenoids andcycled the key to the on position

(engine off). The GPEC did an ini-tial cycling of the solenoids (Figure2). To an eye accustomed to view-ing this type of data two things im-mediately become apparent: Thetypical inductive spike is missing,and all four solenoid voltages arehalf of what they should be (Figure3).

These solenoids are suppliedwith system voltage via a relay.The computer pulses these sole-

5

4

Totally integrated power module (TIPM)

B+ transmissioncontrol output(from relay)

Terminal 3 in C10 connector

Yellow/orange

GPEC

C103T11

C115T20

C101T11

C113T1

To GPEC

40/41TE 62TE

To solenoidbody T4

NGC

continues page 12


13/68

Leave it to Cortecoto introduce a new, easyway to install lip seals and bonded pistonsthat prevents damaging the seal. Introducingthe Lip Wizard, available exclusively inTransTectransmission kits.

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You no longer have to worry about tearing alip seal or buying expensive installation toolsthat only work on specific transmissions. TheLip Wizardis flexible, versatile, reuseableand recyclable. Best of all, its absolutely free.Youll find the new Lip Wizardinstallationtool inside virtually every TransTecgasketand overhaul kit. Visit www.TransTec.com/LipWizard for more information.

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14/68


noids to control shift scheduling aswell as shift feel (clutch pressure). In sodoing, it also continuously checks theintegrity of each of the four solenoidscircuitry by quickly turning the sole-noid off. This causes an inductive spike

(fly-back voltage) that typically is inthe range of 42 volts.

With two issues immediately ob-served, the engine was started (Figure4) and the same two issues remained,even with the alternator now in play.Since all four solenoids were behavingincorrectly in the same way and all fourreceive the same voltage supply, thenext logical diagnostic step is to checkthis common voltage supply.

At this point John referred to a

6

7

C115T20

yellow/orange

S191

S183 S190 S199

Valve-manifold

flowS181 C115 S101 C103

Positive batteryremote post

Negative batteryremote post

Starter wiring

Powertraincontrol module C2

S172

Transmissionwiring

S171

Output-speedsensor

Input-speedsensor

S192

A/C-compressorsolenoid

Generatoreyelet

Generator

Transmission-range sensor

Assembly-linepressure

sensor/variable-force solenoid

Transmissionsolenoid/pressure-switch

assembly

2.0/2.4L

Throttlebody


Transmission Digest12

continues page 20


15/68



16/68


Showpower has established a unique role in the evolving transmissionaftermarket. As retailers have expanded the services offered to maintainprofitable car count, an event that spans the specialty aftermarket segmentsof brake repair, drivability and diagnostics, undercar services and trans-mission diagnosis, rebuilding and installation is a made-to-order weekend.

While the exhibit hall is more intimate than those at AAPEX and SEMA,which feature everything from spark plugs and Turkish trade missions to

air fresheners and key chains, every product dis-played at Showpower is something that an after-market retail shop should definitely consider andperhaps buy. The companies and product linesrepresented in the exhibit hall lead the world insupplying repair components, service tools, andequipment and services that focus on creating amore-profitable shop operation.

Showpower = Shop Power!

Showpo

wer2012Dallas

Hyatt Regency DallasNighttime from atopReunion Tower

Checking InHyatt Regency Dallas

at Reunion

300 Reunion Blvd.

Dallas, Texas 75207

214-651-1234

Showpower Registration & Credential Pickup

Exhibition level of the Hyatt

Wednesday,March 28,5-7 p.m.

Thursday,March 29,

7:30-8 a.m. & 10 a.m.- 5 p.m.

Friday,March 30,

8 a.m.- 7 p.m.

Saturday,March 31,

7:30 a.m.- 5 p.m.

Note: To accommodate tour participants attending Showpower seminars who

prefer not to carry the seminar binder on the bus, a tag redeemable for the

binder will be issued with the badge. The tag may be exchanged for the binder

anytime the registration area is open.


17/68

February 2012 15

Two independently spon-sored events share theDallas destination and head-quarters hotel withShowpower. Participants inthe APRA Volume

TransmissionRemanufacturing Group(VTRG) conference, as wellas those attending the Dallasinstallment of the SonnaxValve Body Roadshow, willautomatically be providedadmission to Showpower ex-hibits. Participants fromthese two groups are wel-come in the exhibit hall dur-ing all regular hoursincluding Friday eveningsAll Industry Reception.

Extra Events

APRA VTRG ClinicCombined Showpower and APRA VTRG Registration & Tour

7:30 a.m. APRA Registration in Exhibition Level(Showpower desk)

8 a.m. -1:30 p.m.

Depart for Showpower/APRA Plant Tours,Lunch hosted by AER

The following events are exclusively for those registered toattend the APRA VTRG Clinic and are separate fromShowpower Expo events.

2 p.m. Introductions/Opening Remarks Jim Slimp,VTRG chairman

2:10 -3 p.m.

Topic to be announced John Schroeder,Jasper Engines & Transmissions

3 - 3:30 p.m. Current State of the Transmission MarketBobby Mace, Publisher, Transmission Digest

3:30-4:30 p.m.

ATF: Why the Right Fluid Is the Right Fluid.The Benefits & Risks of Transmission Fluids toYour Bottom Line.Laurie Strasser, Afton Chemicals

6- 7 p.m. VTRG Welcome to Dallas Reception

7- 8:15 p.m. VTRG Group Dinner

Sonnax spendsa lot of timetalking with trans-

mission specialistsand shop owners.They often know about the Sonnax approachto testing and repairing valve bodies but havelots of questions about how exactly it allworks. Last year Sonnax rolled out itsRoadshow, a series of free seminars that pres-ent valve-body diagnostic and reaming tech-niques to transmission rebuilders across thecountry. After a successful first year, theRoadshow is back with 15 seminars plannedfor 2012, including at events like Showpower.

The Sonnax Roadshow focuses on live in-struction in cutting-edge valve-body repair: di-agnostics and bore reaming. Although manyrebuilders know the basics behind vacuumtesting, they may never have received formalinstruction and are unsure how to make thesetechniques work in their shop. Bore reaming an innovative repair method used by the in-dustrys top transmission rebuilders, special-ists and large valve-body remanufacturers also can be challenging without firsthand ex-perience. These are topics the Roadshow is de-

signed to address, making it a great way foranyone to truly advance their knowledge andskills.

At each Roadshow event, Sonnax intro-duces methods for identifying the root causeof transmission problems, plus repair tech-niques to completely restore and/or upgradeunits. The Roadshows live testing and ream-ing station is the cornerstone of the seminar.Participants see valve bodies tested and re-paired right in front of them, plus get a birds-eye view of the details thanks to a large

overhead video screen zoomed in on theequipment. Participants are encouraged to testand ream units at the workstation themselvesto get a feel for the process while receiving fur-ther hands-on instruction.

The Dallas Roadshow takes place in theHyatt at Reunion, 5:15 p.m. on Thursday,March 29. To register or to see the completeschedule of all upcoming 2012 Roadshow sem-inars visit www.sonnax.com. Upon arrival,participants in the Roadshow should report tothe events registration desk, adjacent to thatfor Showpower 12.

Showpo

wer2012Dallas

APRA VTRG Registration/Hotel

All APRA events take place at the Hyatt. APRA memberswill find their registration desk adjacent to Showpower 12registration. Contact APRA for clinic registration: 703-968-2772. Hotel reservations: Visit www.showpowerexpo.com.


18/68


Two Transmission University seminars, presentedby Jim Dial and Wayne Colonna of ATSG, followthe Bishop and AER plant tours on Thursday. Jimschosen to cover in great detail the specifics of diagnos-ing and rebuilding the Toyota 750E and 761E units. Inthis session he devotes a great deal of attention to un-derstanding how to rework the valve body.

Jim is followed by Transmission Digest TechnicalEditor WayneColonna, who pres-ents a fast-paced lookat a number of popu-lar units including theMercedes 722.9 andthe JF011E CVT that isdeployed in Dodge,Jeep, Nissan andMitsubishi vehicles.

Waynes session

will be followed (inthe same room) by theSonnax Valve BodyRoadshow. Thosewho wish to partici-pate in that Sonnax-sponsored sessionshould reserve a seatby visiting the Sonnaxwebsite, www.son-nax.com.

Thursday after-

noons managementseminars begin withDanny Sanchez pre-senting Ignite theInternet. The sessionis a step-by-step les-son on building a suc-cessful Internetmarketing program.Former shop ownerand TransmissionDigest Business

Editor TerryGreenhut followswith The Cost ofDoing Business. Helldiscuss pricing, break-even analysis and the road toprofitability.

The undercar technical sessions include UndercarDigest Technical Editor Ron Henningsen withUnderstanding and Diagnosing Wheel-SpeedSensors and Tim Janello, automotive instructor atSouthern Illinois University-Carbondale, who discuss-es servicing high-voltage batteries on Toyota models

with Generation I and II battery cells.

Thursday Seminars

Theres absolutelynothing better thanwinning a little cash unless its winning a lotof cash. During the Top10 luncheon on Friday

and then hourly duringexhibit-hall hours bothFriday and Saturday,there will be drawingsfor a $500 check. Towardthe end of the day onSaturday, the prize potwill increase to $5,000.

Your chances to claima prize are excellent, butyou must be present towin.

The cash prizes areprovided on behalf ofthe exhibiting companiesas an added incentive forShowpower participantsto visit with them in theexhibition hall. Checkout the booths each day,as many of those exhibit-ing suppliers have addi-tional daily prizedrawings within their

display areas.

Cash Call

Handouts and note-taking materials areprovided by MagnaFlowfor undercar and man-agement sessions and byATSG for transmission

sessions.

Helping Handouts

Thursday Schedule

7:30 -8 a.m. Badge Pickup

8 a.m. Buses Depart for Tour

8:30 a.m.- 1:30 p.m. Tour & Lunch

10 a.m. - 5 p.m. Registration

2-3:20 p.m. Seminars Session I

3:20 -3:40 p.m. Refreshment Break

3:40 -5 p.m. Seminars Session II

Showpo

wer2012Dallas


19/68

February 2012 17

Participants shouldnote that FridaysTransmission Universitysessions start earlier thando the management and

Undercar sessions to pro-vide extra time for diag-nostic guru G JerryTruglia. Gs plan calls fortips on developing a diag-nostic strategy for pre-dominantly Asianvehicles.

The popularTransmission Digest col-umn TASC Force Tipscomes to life with a pres-

entation from BobWarnke, Sonnax vicepresident of technical de-velopment. Bobs sessioncovers valve-body controlof the TCC in units in-cluding ZF 6HP, AW6FWD, Ford 5R110,Mercedes 722.6, GM 6L80-E and others.

Friday managementsessions bring a pair of

AMI-qualified sessionsfrom management trainerMaylan Newton.Maylans first session hassome motivational as-pects as Success or Struggle explores the way inwhich personality and attitude can shape a busi-nesss success.

After a coffee break, Maylan continues with avaluable session named Confident Selling DoYou Believe? Nothing is more important to thesuccess of a business than the ability to communi-

cate with the customer and close the sale.

Each year the readers ofTransmission Digest se-lect from nominated prod-ucts and tools The Top 10Products and Top 10 Tools ofthe year. The readers ofUndercar Digest do the same.

It is an honor to be favored insuch a manner by retail repair facili-ties within the industry. The Top 10luncheon celebrates the winners ofthese awards for 2012. The programalso includes a nationally renowned Showpower favorite,Sid Hurlbert. Sid uses participation and humor to sharesome methods of how to deal with difficult business situa-tions involving both customers and employees.

Immediately after Sids session, the exhibit hall opensfor Showpower 12.

Best In Show

Whenever the industry gath-ers there are activities thateveryone enjoys looking attools, products and equipment;socializing; eating; and drinking.

The All-Industry Reception, spon-sored by Transmission Digest andUndercar Digest, combines it all.

Pick up a plate of food and abeer or soft drink in the exhibit-hall center lounge while you shopthe exhibits or sit at a family-styletable with other participants toenjoy a snack and some conversation.

The Friday-night All-Industry Reception takes placeinside the exhibit hall from 5 to 7 p.m. This event is free toall Showpower, APRA and Sonnax Roadshow partici-

pants.

Friday Seminars Fridays Schedule8 a.m. -7 p.m. Registration

8 -9 a.m. Continental Breakfast

8:30 -10:20 a.m. Transmission SeminarsSession III

9 -10:20 a.m. Undercar & ManagementSeminar Sessions III

10:20 -10:40 a.m. Refreshment Break10:40 a.m.- 12:30 p.m. Seminars Session IV

12:30 - 2:15 p.m. Top 10 Awards Lunch

2:30-7 p.m. Showpower Exhibits

5 -7 p.m. All Industry Reception

Showpo

wer2012Dallas

All Industry Reception


20/68


As on Friday, SaturdaysTransmission University semi-nars start 30 minutes earlier thanother sessions. The extra time willallow industry-renowned trainerJohn Thornton to more-fully ex-

plore diagnostic issues and proce-dures on VW 01M and 09G units.John focuses on use of the VDCSusing lab-scope patterns that sup-port the scan-tool discussion. Healso will cover TCM coding, KOEObidirectional control tests, basicVDCS settings and how to log data.

The days second session fea-tures a different John, JohnParmenter, who appears courtesyof the Precision InternationalAdvisory Board. Johns session isalways called The BuildersBench and features tips and pit-falls John has discovered duringthe past year working for Precisionor at his Long Island shop.

Y, una sesin mas: The technicalseminars conclude with a discus-sion all in Spanish of various prob-lems fielded by ATSGs hotline.Jos Garca will conduct a sessiondesigned exclusively for Spanish-speaking technicians.

The management track offers anequally impressive lineup, includ-ing Undercar Digest BusinessEditor Tom Langer moderating asshop owners Rich Fearing, RickBettger and Rick Stephenson sharethe decisions they made to taketheir shops to the next level.ASAs Bill Haas is next with a fol-low-up to last years seminar onworking with generations X and Y.Nationally known motivational

speaker Sid Hurlbert ends the daywith an amusing but informational talk on makingmoney and having fun at the same time.

Undercar sessions include Delphis Dave Hobbsproviding insight into antilock-brake theory, operationand diagnosis. Those interested in custom exhaust willwant to attend the hands-on bending clinic on the ex-hibit floor, where they can try out a Huth or BenPearson bender to custom-bend tubing provided cour-tesy of Atlantic Tube & Steel. Gary Hershberger ofHunter Engineering follows with a collection of proce-dures and tips that every alignment technician should

know. TD

Saturdays Schedule

7:30 a.m.- 5 p.m. Registration

7:30-8:30 a.m. Continental Breakfast

8-9:50 a.m. Transmission Seminar Session V

8:30-9:50 a.m. Undercar & ManagementSeminars Session V

9:50-10 a.m. Refreshment Break

10-11:30 a.m. Seminars Session VI11:30-11:40 a.m. Refreshment Break

11:40 a.m.- 1 p.m. Seminars Session VII

1 -2 p.m. Passport Lunch

1-5 p.m. Showpower Exhibits

5:30 p.m. Buses depart for SpeedZone

6-9 p.m. SpeedZone

Over the years, one of the mostfun events hosted at Showpowerhas been the SpeedZone racing. Thisafter-hours event gives everybody a chance to relaxand get to know one another better.

After exhibitsclose on Saturday,buses will be de-parting for theSpeedZone tracks,

where participantswill have the op-portunity to raceminiature go-cartracers on a variety of tracks including Thunder Road;Top Eliminator dragsters; Slick Trax drift-style racing;and the 20-vehicle wheel-to-wheel Turbo Track.

Admission to this separate-purchase event Saturdayevening includes an informal dinner buffet and the op-portunity to sample the tracks and to race against eachother and the clock.

Becoming Fast

Friends

To accommodate the schedule for a third Saturdayseminar session, the exhibition opens immediatelyafter the seminars. Everybodys going to be hungryabout that time.

Each seminar participant will be provided a ticket atbadge pickup. That ticket is redeemable in the exhibi-tion hall for lunch on Saturday. Those who arent par-ticipating in the seminar programs can access the

lunch on a cash basis.

Saturdays Line on

Lunch

Showpo

wer2012Dallas

Saturday Seminars


21/68

APRA/Showpower Factory Tour

S e m i n a r p a r t i c i p a n t s c a n t a k e t h e T h u r s d a y m o r n i n g t o u r t h a t i sp a r t o f t h e A P R A V o l u m e a n d H e a v y - D u t y T r a n s m i s s i o n d i v i s i o n

m e e t i n g s t h a t w i l l t a k e p l a c e d u r i n g S h o w p o w e r . W e d e p a r t b y

m o t o r c o a c h f r o m t h e h e a d q u a r t e r s h o t e l , t h e H y a t t R e g e n c y

D a l l a s , a t 8 a . m . T h e f i r s t t o u r s t o p i s B i s h o p I n t e r n a t i o n a l ,

w h e r e w e l l s e e t h a t c o m p a n y s a u t o m a t i c - t r a n s m i s s i o n h a r d - p a r t s

o p e r a t i o n a n d t h e m a n u a l - t r a n s m i s s i o n r e m a n u f a c t u r i n g l i n e s .F r o m B i s h o p w e l l c o n t i n u e o n t o v i s i t t h e s t a t e - o f - t h e - a r t a f t e r m a r k e t e n g i n e - r e m a n u f a c t u r i n g f a c i l i t i e s o f A E R . I n a d d i t i o nt o t h e e n g i n e s , A E R i s a F o r d A u t h o r i z e d D i s t r i b u t o r a n d h a s al i n e o f r e m a n u f a c t u r e d a f t e r m a r k e t t r a n s m i s s i o n s f r o m i t s p l a n t i ns u b u r b a n C h i c a g o . A E R w i l l h o s t a l u n c h f o r t h e t o u r g r o u p a n do p e n i n g i t s p r i v a t e c o l l e c t i o n o f c l a s s i c c a r s f o r u s t o e n j o y .

Sonnax Road Show at Showpower

V i s i t i n g s e v e r a l m a j o r c i t i e st h i s y e a r , t h e S o n n a x V a l v eB o d y R o a d S h o w s t o p s i nD a l l a s d u r i n g S h o w p o w e rE x p o . D a l l a s M e t r o p l e x t e c h n i c i a n s a n d t h o s e a t t e n d -i n g S h o w p o w e r a r e w e l c o m e t o a t t e n d . S o n n a x T A S CF o r c e e n g i n e e r s p r e s e n t a n i n - d e p t h h a n d s - o n - s t y l e s e s s i o n

o n v a l v e - b o d y r e p a i r s i n c l u d i n g r e a m i n g . T h e R o a d S h o w

s e s s i o n i m m e d i a t e l y f o l l o w s o p e n i n g - d a y t r a n s m i s s i o n

s e m i n a r s o n T h u r s d a y , M a r c h 2 9 , a t 5 : 1 5 p . m .

Everybody

Does Dallas:

Everybody

Does Dallas:

And Youre Cordially Invited:

See Showpower insert in this issue


22/68

wiring diagram (Figure 5) and decided tocheck this power source at connectorC115, terminal 20, on the relay side of theconnector (figures 6 & 7). With the scopehooked up to both the power source andthe low/reverse solenoid on the oppositeside of the connector and the ignition

turned on, you can see full power to theconnector with a voltage drop to thelow/reverse solenoid still present (Figure8). You can also see how quickly the com-puter recognized a problem, as evidencedby the power supply going to 0 because ofthe relay being turned off.

This indicated that there might be aproblem with the connector itself, so Johnquickly put a jumper wire in place (Figure9). Once this was done, the low/reversesolenoid came back to life, being pulsed on

and off at full battery voltage along with a45-volt inductive spike (Figure 10). Withthis inductive spike the computer can de-termine the integrity of the circuit. If itstoo high or too low, the P0750 code sets.With the old 60-way TCM this spike isaround 42 volts. With this new GPEC (inuse since the 2007 model year) the spike isnot as loaded down so it hits the 45-voltmark.

The one question you may be askingyourself is if all the solenoids were affect-ed by a common power supply, why didonly P0750 come up? This is a good ques-tion. When these vehicles start up, the

low/reverse solenoid is thefirst one the computer looks at.If there is a hard fault with thiscircuit, the low/reverse codewill set before the computerlooks at any others. This mayexplain why in the past youmay have seen a wire problemfor the low/reverse solenoid.After it was repaired, you sud-

denly had another code for the2-4 solenoid, as it too had awire problem. Since thelow/reverse set first, the com-puter didnt look further. Oncelow/reverse was repaired, thecomputer then moved on tothe next solenoid to bechecked, the 2-4.

The correction for this vehi-cle was to do a simple, inex-pensive, 30-minute repair of

the connector. TD

8

9

10



continued from page 12


24/68


The RE4F03/4Btransmission inseveral Nissan

vehicles develops a hard1-2 upshift as a result ofuncontrolled line pres-sure. Sometimes codeP0745 is stored for aproblem in the line-pres-sure-control solenoidcircuit. Replacing the so-lenoid assembly usuallyfixes the problem. But,the next time this hap-pens to you, or you getto experience this for thefirst time, the fix may be

as simple as gentlysqueezing a crimp.

The pressure-controlsolenoid is grounded in-ternally through an eye-let bolted to the valvebody (Figure 1). Removethe bolt and tug on thewire to see whether thecrimp is clamped downinto the wire properly(figures 2 and 3). There

are instances in whichthe crimping process didnot clamp it down suffi-ciently and the wire be-comes loose. If youdiscover a loose-fittingwire, give the crimping agentle squeeze to restoretight contact. There maybe instances in which alittle solder would be inorder.

Also take a look at the

3

4

2

1

6

5

Shift Pointers

Subject:

Hard 1-2 upshift

Unit:

RE4F03/4B


Nissan

Author:

Wayne Colonna, ATSG

Transmission Digest

Technical Editor

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & RTECHNICAL

TRAINING

A Hard ShiftFixed by a Gentle Squeeze

crimp where the wires come out of the so-lenoid (Figure 4). If this has been lifted up,give it a gentle push down (figures 5 and6). This will take tension off the wire, giv-ing it the slack it needs to prevent vibra-

tion from pulling it loose again. TD


26/68


Taking it to the Track, Part II:

Our Charger Runs the Quarter MileThe sheriff now wins more than half of his races

I

n my previous installment(November 2011), I profiled our

progress of hot-rodding apart-time sheriffs car for our localone-fourth-mile drag strip,Bandimere Speedway.

Our speedway hosts a programcalled Take it to the Track, aninitiative aimed at getting youngdrag racers off the street and ontoa safer venue, and this 2006 DodgeCharger just needed its exhaustsystem installed before we couldstart the engine.

To recap, here is the list of after-market, high-performance partsthat we were charged with in-stalling:

A higher-lift roller camshaft andnew roller lifters

A higher-stall torque converter

A cold-air intake and filter

A larger throttle body

Headers and a cat-back exhaustsystem

A Diablosport hand-held flashreprogrammer

A new ring-and-pinion set witha 3.68 gear ratio

Full engine-gasket set, fluidsand filters.

Two months of part-time volun-teer labor had been invested in thispolice car, and we were itchin tohear it run!

Figure 1 shows the cat-back

stainless-steel exhaust with high-

flow mufflers and an X-pipecrossover. My understanding of

this type of exhaust crossover isthat the X-type promotes im-proved scavenging effect bysmoothing out uneven exhaustpulses, whereas the H-typecrossover is less efficient, as thegases would rather take the path ofleast resistance, which is straightdown the exhaust pipe. I have evenread articles comparing these high-performance exhaust systems to noexhaust at all, and often there is noreduction or addition in horse-power with the new exhaust,which is pretty amazing!

Once we started the engine, wewere greeted with a nice, mellowexhaust rumble, one you couldhear from inside the car. It got

louder and better with accelera-tion. Because we had installed non-

MDS valve lifters (Our 5.7-literHemi engine includes a uniquefeature - the multi-displacementsystem [MDS] that deactivatesfour of the eight cylinders whenthe throttle is closed or at steadyspeeds. This is accomplishedthrough the use of dual-modelifters and four solenoids that re-duce oil pressure from 16 psi to 3psi to close the intake and exhaustvalves on cylinders 1, 4, 6 and 7),we had a permanently illuminatedMIL (malfunction indicator lamp).For our purposes, as long as weknew the root cause of the MIL, wewerent concerned, as this wouldnot affect the intended purpose ofour vehicle. I dont like having thissituation; however, I am not awareof a simple way to circumvent thissystem and make the powertraincontrol module (PCM) happy.

Once I talked our sheriff into let-ting me test-drive his cruiser, I did

so as much as I could! I have to saythat everyone else on the roaddrove extremely well when I waswithin sight.

Once I finished having a littlefun with my friends and neigh-bors, I was able to make some ad-justments to the PCM with ouraftermarket flash programmer.This was my first foray into thisstyle of aftermarket flash program-ming, and I was excited to see the

1

2011 AutoInc.

Tech To Tech

Subject:

Transforming a retired patrolcar into a drag racer


2006 Dodge Charger

Author:

Brian Manley

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & RTECHNICAL

TRAINING

continues page 26


27/68

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28/68


Tech To Tech

list of items that Iwould be able totweak:

Idle rpm indrive/neutral

Wide-open-throttlefuel 1K-3.8K/4K-

5K/5K-7K (Figure 2)

Rev limiter indrive/neutral(Figure 3)

WOT spark 1K-3.8K/4K-5K/5K-7K

Cooling-fan adjust-ment

Tire size

Axle ratio (Figure 4)

Shift points Shift firmness

MDS enable/disable

Transmission con-trol module adap-tive reset

I adjusted those thatI felt necessary: I raisedthe rev limiter, in-creased the WOT fueland spark, adjusted the

tire size to reflect thecurrent treads,changed the axle ratioto the new 3.68 gearratio and raised theshift points. I onlywish I had the time torun a few horsepower pulls on myfriends Mustang dynamometer,and then adjust individual lineitems to see what effect it wouldhave on horsepower and/or one-

quarter-mile times.Once we had the Charger run-ning and put some miles on it, thesheriff came to pick it up. He sur-prised us when he asked all of ouryoung technicians to sign the carswing with a permanent marker(Figure 6) a nice touch for thosewho donated so many hours to thisendeavor.

The ultimate test for our race carproved to be the most fun: taking it

to the track! We met the sheriff at a

test-and-tune night at BandimereSpeedway and proudly watchedour car pre-stage, stage and thenrun a one-quarter-mile pass (fig-

ures 7 and 8). The Charger ran a

solid 15.18 seconds and 93 mph(Figure 9). Faster passes wouldcome as we experimented with theflash programmer, and we had alot of fun racing an eclectic mix of

Detroit muscle and import cars.

Conclusion:As an ASE-certified diagnostic

and repair technician, I often usemy skills to diagnose no-starts orto R&R clutch assemblies more-normal vehicle repairs.However, this project gave all of uswho worked on it a rare opportu-nity to see what $5,000 of speedequipment can do to a stock

7

8

62

3

4

5

continues page 28


29/68

shington, D.C., RepresentationAs experienced, full -time Washington, D.C., representative works onalf of ASA members and for local groups when regional issues arise.

tworkingput you in touch with your peers to work together to solve the issues

ng todays automotive repair professional.

ney-saving Products and Services member of ASA, you gain access to more than 35 benefit

grams, products and services designed specifically for automotive

air businesses.

Education

ASA offers unbeatable management education and technical trainingopportunities to enhance your business credibility.

InformationASAs publications and resource centers give you instant access toinformation such as technical articles, training seminars, and legislativeand industry information.

Automotive Service Association

ASA is the largest not-for-profittrade association of its kind

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Join us!

Automotive Service Association(ASA) (800) ASA- SHOP www.ASAshop.org

hen you see all that we have to offer, youll find there is significant value in ASA membership.



30/68

Charger. Ultimately, the one-quarter-mile time for ourCharger dropped from 15.9 to14.8 seconds (at 6,000 feet of ele-vation), and the miles per hourjumped from 87 to 96 at the endof the track.

Our sheriff now wins a little

more than 50% of his races compared with 30% beforemodification. Plus, he enjoysbeing more competitive. And,the sheriff is happy with the re-sults and has a smile on his facewhen he leaves the track.

Were happy for him, andwere proud we can supportsuch a worthwhile cause.

Brian Manley is a vocational automotive

instructor for the Cherry Creek school districtin Aurora, Colo. He is an ASE master certifiedautomobile technician and a former member ofthe National Automotive Technicians

Education Foundation (NATEF) board oftrustees. You can reach him [email protected].

This copyrighted article is reprinted with thepermission of AutoInc., the official publicationof the Automotive Service Association (ASA).

To learn more about ASA and its commitmentto independent automotive-service and repairprofessionals, visit www.asashop.org or call

800-272-7467.

TD

9

Tech To Tech


Once More,

Not the Transmission

Its very simple to get steered inthe wrong direction whenyoure diagnosing a transmis-

sion complaint. There are so manydifferent sensors and componentsthat can cause transmission-likesymptoms that at first it seems as ifwithout a doubt you have a trans-mission problem, and from a cus-tomers perspective they areconvinced its going to cost them anarm and a leg, which provides youthe opportunity to be a hero andgain a customer for life.

A couple of years ago I recallreading an article by WayneColonna that pointed out severalexternal factors that can producesymptoms that seem to point topossible internal transmission

problems. In this article we want totalk about another unlikely compo-nent that can send you into a diag-nostic tail spin: the alternator.

A common complaint of a cy-cling torque-converter lockupand/or fourth-gear hunting withno codes on Dodge diesel truck ap-plications can be caused by a badalternator diode. During cruise adefective diode can allow for highvoltage spikes to occur, causing

electrical noise within the TPS cir-cuit. Also youll find that Dodgeran the TPS wiring harness along-side the alternators wiring harness,which can cause electrical noise tobe induced in the TPS circuit.Besides the obvious havoc that apoor charging system, bad diodesand bad grounds can have on a ve-hicles electrical system, it can alsofail mechanically.

Heres something I wasnt aware

of until recently, a trend of several

R&R Tech

Subject:

Transmission-likesymptoms producedby alternatorproblems

Author:

Mike Steen

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & RTECHNICAL

TRAINING

continued from previous page

vehicle manufacturers using whatscalled an isolator decoupler pulley(IDP). The IDP is an improvementon the overrunning alternator pul-ley, which has been around since1990. Basically its an alternatorpulley that works in the normalway except it has a one-way clutchthat allows the drive belt to free-wheel under certain conditions,such as sudden engine decelera-tions. Incorporating the overrun-ning alternator pulley or an IDPeliminates belt noise; it also re-quires less belt tension than theprevious systems. Less tensionmeans fewer loads and less fuelused.

One of the most-common prob-lems with these systems on higher-

mileage vehicles is bearing noise. Aworn bearing can cause a briefnoise when you shut the engine off.Another possibility is that a cus-tomer might complain of a noiseduring the 1-2 shifts. This com-plaint is more likely to come from adriver with a heavy foot whomakes a lot of wide-open-throttleupshifts. One thing to keep in mindis that the engine decelerates rapid-ly during hard shifts. If you suspect

a bad bearing, have someone revthe engine and then quickly shutthe ignition off while you listen fora noise at the front of the alternator.

Diagnosing these would-betransmission problems can be achallenge, but also rewarding. Itsone of the best ways I know to get acustomer telling everyone theyknow how great your shop is!

Mike Steen is the manager of CertifiedTransmissions Technical Department.

TD


31/68

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Whatever It Takes2012 Vehicle to AutomaticTransmission Guide

Whatever It Takes 2012 Vehicle toAutomatic Transmission Guide (TrannyGuide) is a pocket sized flip Chart thatallows the user to identify whichtransmission a vehicle has based onMake, Model, Year and Engine sizeinformation. These Guides includeinformation on vehicles from all themajor manufacturers through the2012 model year.

Whatever It Takes Transmission 2012 AutomaticTransmission Parts Catalog

Whatever It Takes Transmission2012 Parts Catalog features photobreakdowns of over 100 of the newestForeign & Domestic transmissions.Every two page spread provides partnumbers & complete photo break-downs of the unit assembly. WIT alsooffers the catalog in CD format, whichalso includes Tranny Guide, themost up-to-date vehicle to automatictransmission index in the industry.This CD allows you to quickly retrieveimportant information with just a clickof a button.

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available to transmission-repair facilities.

Thanks to all our readers who took the time to vote.


33/68

February 2012 31

Sonnax SmartShell 77749-02KThank you for showing us you understand and appreciate what we did.

There are many options out there to address known weaknesses in the4L60 series sun shell. They come in a variety of bigger, meaner andtougher. What makes ours stand out in the field of brawny tough guys isthe fact that we cured a second common problem at the same time. Onlythe SonnaxSmartShell77749-02K addsthe strength whereit is needed plus

eliminates rearplanetary captivebearing burnout.We are glad younoticed.

Sonnax Line Pressure Booster KitsAdding a little line pressure can be a good thing. The question has

always been, how much and when? Rebuilders have told us that Sonnaxline pressure booster kits not only answerthe question but get it right every time.Our simple, easy-to-install kits areavailable for a variety of popular unitsand eliminate the trial and error and

compromises associated with just replacingthe PR spring. Why settle for the high-endpressure you want while having to acceptharsh shifts at light throttle? Sonnax linepressure booster kits give you a modestincrease from the onset and all you canhandle at wide-open throttle.

Superior K080 727/518/618 Super Servo 11% More

Holding Power Firmer 1-2 Shift More Positive

2-3 Shift Perfect for

Heavy-Duty andPerformanceApplications

Includes Heavy

Duty Band Strut

Adapt-A-Case BRNY NP246/NP261/NP263Case Protector

Permanent pump wear protection. Good used case halves are achallenge to find. New aftermarkets are available, for a price. The problemwith merely replacing the case is it wontsolve the problem. Magnesium casesare soft; aluminum pumps are harder.The problem leak will come back. Save

your customer money and fix theirproblem the first time with this simpledrop-in: 1) Clean case and repair dam-age with an epoxy, or you may chooseto have welded. 2) Place BRNY protectorin the pump pocket. 3) Continue therebuild knowing its fixed. US Patent#7,740,458/Canadian Patent #2,579,455

Whatever It Takes2012 Vehicle to ManualTransmission Guide

Whatever It Takes 2012 Vehicle toManual Transmission Guide (TrannyGuide Standard Edition) is a pocketsized flip Chart that allows the user toidentify which transmission a vehiclehas based on Make, Model, Year andEngine size information. These Guidesinclude information on many newlyreleased 2012 vehicles from all themajor manufacturers.

Whatever It Takes Transmission 2012-2013 StandardTransmission Parts Catalog

Whatever It Takes Transmission2012-2013 Standard TransmissionParts Catalog features photo break-downs of the newest Foreign &Domestic transmissions. Every twopage spread provides part numbers &complete photo breakdowns of the unitassembly. WIT also offers the catalogin CD format, which also includesTranny Guide, the most up-to-datevehicle to standard transmission indexin the industry. This CD allows you toquickly retrieve important informationwith just a click of a button.

Whatever It Takes2012-2013 Vehicle toTransfer Case Guide

Whatever It Takes 2012-2013 Vehicleto Transfer Case Guide is a pocket sizedflip Chart that allows the user to identifywhich transfer case a four-wheel-drive orall-wheel-drive vehicle has based onMake, Model, Year and Transmissioninformation. These Guides includeinformation on vehicles from all themajor manufacturers through the2012 model year.

Top10ProductsWinners

Top10ToolsWinners

Arizona Transmission Machine EZ-DRIVERArizona Transmission

Machines EZ-DRIVER allowstechnicians to create morethat 200 different installers forbearings, gears, seals, hubsand sleeves. Increases shopproduction and is a shopnecessity no matter what yourspeciality is. EZ-DRIVER ismade in the USA and hasreceived multiple awards anda United States Patent in2011. Available atwww-ez-driver.com orMike Tilley, 602-992-2961.


34/68


Superior K092 4R70E/W & 4R75E/W SuperToughPlate

The SuperiorSuperTough Plate for2001-up 4R70E/W &4R75E/W is zinc coated,extra thick and is the perfectreplacement for the stockvalve body separator plates.This plate eliminates crackingand cross leaks caused by

constant pounding from the2-3 Accumulator PistonSpring Retainer on the stockseparator plate. Snubberincluded.

Superior K098 4T65-E AFL Valve Repair KitThis kit addresses the leaking AFL Signal/Balance Oil that sets various

codes, most notablythe P1811 Maxadapt or long shiftcompletion, orvarious TCCslip/error codes.

This problem canalso cause 2nd-gearstarts. The newlydesigned AFL valveand spring comboalong with a simplecup plug will stop theleak and the code!

Rockland Standard GearNV 136, 149, 236, 246, 261 & 263 Rear Cases

Unlike the offshore product that is being sold, these Tranzilla heavyduty cases are manufactured in the USA from aircraft grade aluminum,replacing the failure prone OEM magnesium product. These case halvescome with a lifetime warranty against oil pump beat through and bear-ing creep commonwhen steel bearings

meet a magnesiumcase. Three partnumbers 25900TZ,30603TZ & 31334TZ replace all OEMpart numbers, whichmeans you have lessinventory to stock.

Transtar StandardTransmission and TransferCase Parts Catalog

Featuring line drawings andcomponents for nearly 100 standardtransmission units and approximate-ly 40 transfer case units, TranstarsStandard Transmission and TransferCase Parts catalog is the mostcomprehensive in the industry. Withover 30 different charts and illustra-tions, and unit identification pictures,Transtar can help you identifypopular and difficult-to-identify itemsand the unit you have in your shop.

Transtar AutomaticTransmission Parts Catalog

Transtars Automatic Transmission

Parts catalog is the most accurate,up-to-date and comprehensivecatalog in the industry. Coveringover 150 different transmissions,this catalog features several newadditions such as fifteen newtransmissions. Organizedalphanumerically for ease of use, thecatalog also now includes OEM refer-ence numbers, terminology pages,technical manuals and a transmissioncode section which includes alterna-tive names for transmissions.

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TranstarStandard Transmission andTransfer Case Units byVehicle Guide

With over 1,400 popular andunusual applications, TranstarsStandard Transmission and TransferCase Units by Vehicle Guide is themost comprehensive guide in theindustry. Standard transmissions andtransfer case units are identified in theguide by year, make, model and enginesize making it easy to locate theinformation you need. This pocket-sized tool is a must-have for shops.


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February 2012 33

Superior K4F27E 4F27E/FNR5Shift Correction Package

This valve body kitdeals with these problems: Soft shifts and flairs Premature band failure Code P0741

(TCC slippage) Broken solenoid PR

valve spring Worn or damaged

accumulator boresThe kit includes

Accumulator Buddy Tooland newly designedaccumulator pistons.

Whatever It Takes Transmission PartsOE CVT Push Belts

Whatever It Takes Transmission parts is now a Distributor of Bosch OECVT Push Belts. Applications include GM, Saturn, Nissan, Honda andothers. www.wittrans.com, 800-940-0197

Superior K060 Line Pressure Relief ValveThe Superior Line Pressure Relief Valve is the popular choice of R&R

men and rebuilders everywhere.Featuring its unique no-stickblow-off-ball design, its alsocompletely assembled andready for drop-in replacementand ensures consistent

pressure control and properinitial engagement; thats whybuilders love it. R&R men like itbecause they dont have to keeppulling the unit back out due tosticking, so you wont have toR&R it twice. Thats why wecall it The Simple Solution.

Teckpak 31284G 4L60-E/4L80-E Cooler Line RepairFitting

Repair fitting for 4L60-Esand 4L80-Es with clip-incooler lines. You, ourcustomers, asked for a repairfor the clip-in cooler in the4L80-Es in the rear. We cameup with the 31285G, whichmade many happy, but somesaid what about the other

cooler line. So now you haveit, the repair fitting so you canuse the standard 38- inch flaredbrake line as a replacement forthe OEM line when it fails.

Filtran2011-12 AutomaticTransmission Filter Pocket

GuideFiltrans industry leading Automatic

Transmission Filter Pocket Guide has beenupdated for 2011-12. In addition to newapplication listings the catalog includesdetailed filter information including OEnumber, application coverage, fluidcapacity and type along with a guidefor use of Lubegard transmissionproducts.

New TransTec Global EditionTransmission Guide

Identify automatic transmissions invehicles throughout the world with a new,global-edition Transmission Guide fromCorteco, supplier of TransTec brand kits.Developed specifically to eliminateconfusion over look-alike transmissions,this 70-page reference identifiestransmissions by vehicle make, model,year and engine for import and domesticapplications through the 2012 model year.You can select Ford, for example, todetermine that a 2002 Ford Explorer witha V-6 4.0L engine has a 5-speed rear-wheel-drive transmission (model 5R55W).

Arizona Transmission Machine 6L80-E PumpAlignment Clamp

Arizona Transmission Machine Inc. has introduced a 6L80-E pump-

alignment clamp. Made in the USA from 6061 T-6 billet aluminum, theclamp is precision machined tomate with the pump body (bell-housing) and stator support forproper alignment of both partsduring reassembly. The ATSGservice manual says pumpalignment on this unit is critical.To keep the cost as low aspossible, the clamp comes ina really nice cardboard box.Available at www-ez-driver.comor Mike Tilley, 602-992-2961.

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36/68


The New Venture 247 transfercase was used in the JeepGrand Cherokee (WJ) vehicle

in the 1999 to 2004 model years.Nobody throws away a Jeep, and

these units create a lot of repairwork and parts sales. They alsogenerate an inordinate amount oftech calls as a result of the prob-lems with the design and misun-derstood theory of operation. Thisarticle will concentrate on the areasthat cause shops the most troublein diagnosis and repair.

The 247 is an evolution of de-sign that started with units usingviscous couplings. The viscous

coupling would react to differ-ences in wheel speed between thefront and rear axles and sendpower to the wheels that needed it

until the slippage stopped and theshaft speeds equalized front torear. These units were extremelysusceptible to differences in tiresize front to rear, and tires withmore than 14 inch difference in cir-cumference would have the vis-cous coupling working overtime tocorrect a slip that wasnt there.This failed the viscous couplingquickly, creating another expen-sive repair.

To advance the engineering,New Venture replaced the viscouscoupling with what it called aprogressive coupler or pumpcoupler (Figure 1). Under normalroad conditions most of the torqueis applied to the rear wheels; whena speed difference between thefront and rear wheels occurs, the

progressive coupler acts as a dif-ferential to send power to the axlewith better traction, eliminatingwheel spin and restoring control

with no driver input.In the NV 247 there are two

gerotor-type pumps. The main, orlift, pump (Figure 2) takes fluidfrom the sump and forces itthrough the bearing bores and sup-plies the pump coupler or progres-sive coupler with pressurized lube.The coupler is a sealed, non-serv-iceable unit that contains a secondgerotor pump and a clutch pack,piston and pressure plate. The as-sembly acts as a differential, andwhen there is wheel slip the differ-ence in shaft speeds puts the pumpto work pressurizing the clutchpack and sending power to thefront axle. When the shaft speedsequalize, the pump stops working,the pressure bleeds down andpower reverts to the rear wheels

only.Sophisticated orifices and valves

inside the coupler make this hap-pen in an orderly fashion, and

21

Up To Standards

Subject:

Diagnosis and service

Unit:

NVG 247


1999-2004 Jeep Grand Cherokee

Author:

Mike Weinberg,RocklandStandard GearContributing Editor

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & RTECHNICAL

TRAINING

TRANSMISSION DIGEST

TECHNICAL

FIELD FIX

1 oil pump2 tube O-ring3 oil pickup tube

1

2

3

Fine-Tuning the NVG 247 Transfer Case

Courtesy of Chrysler Group LLC Courtesy of Chrysler Group LLC


37/68

February 2012 35

these units suffer badly from dirtand worn-out or insufficient lube.This creates an expensive repair, asthe progressive coupler must be re-placed as an assembly. This part (#5012329AA) sells at the dealer forabout $686, and the failure rate is

high enough for aftermarket com-panies to tool up to manufacture itat a price in the $363 range, a sav-ings of about $320. Whats not tolike?

However, there are is-sues that need to be re-solved here, as there aretiming differences be-tween OEM and after-market progressivecouplers. In our research

we have found that theOEM coupler needs aboutthree or four revolutionsto activate. That windowis designed to compen-sate for slight normal dif-ferences in wheel speed.The common complaintwith the aftermarket cou-pler, which has a moreinstant-on timing, is bind-ing on turns, especiallywhen its new with maxi-mum coefficient of fric-tion in the clutches. Thiswill create an issue foryou with a customer whohas just plunked downhis life savings to pay forthe repair.

On top of that, many ofthe WJ-series Jeeps werebuilt with what is calledQuadradrive. This sys-tem uses progressive-

type couplers in the frontand rear differentials tomake them limited-slip.The differentials in bothaxles also use hydraulicpressure to apply theclutch packs for limitedslip, and they are ex-tremely prone to worn-out fluid or dirt andcontamination from off-road use. Do not just con-

demn the coupler in the

transfer case without making sureboth differentials are functioningproperly and are full of the specialfluid required and that the fluid isnot burnt or oxidized.

Another issue occurs whenthese differentials are serviced and

the builder applies too much RTVto seal the case. Excess RTV can falloff internally and clog the orificesand create a fully locked differen-

tial that is unable to bleed off pres-sure. This will cause enough of abind to literally stop one of thesevehicles in a turn.

So we want to use an aftermar-ket progressive coupler in thetransfer case, but we do not want

to deal with a binding condition onturns. Here are the steps to take tosolve this problem and get the cus-tomer happily on his way:

1. Always measure the circumfer-ences of all four tires with astagger gauge ($50). Any differ-ences of more than 14 inch willrequire tire replacement, as thisalone can fail the progressivecoupler.

2. Disassemble the gerotor lift

pump for cleaning and inspec-tion. This pump is also sold onlyas a complete assembly; no serv-ice parts are available.

3. Using a die grinder or a hack-saw blade, cut a bleed notch(about 18 inch) in the pump sur-face (Figure 3). This allows oil tobleed off more quickly andcures any timing problems thatmay influence the release rate ofthe progressive coupler.

Reassemble the pump.

4. Make sure to use the correctfluid for the 247, and when in-stalling either OEM or aftermar-ket progressive couplers soakthe unit overnight in the correctlube to get the clutches wet andremove any air trapped in thefriction material or coupler.

5. Road-test the vehicle makingmoderate to tight turns for a few

miles to make sure that the cou-pler is releasing properly. Someslight initial binding is normalbut should go away within afew miles of driving.

Understanding the theory of op-eration, being aware of the sensi-tive nature of the Quadradrivesystem, and recognizing the criticalimportance of tire sizes for correctoperation of the vehicle will go along way to sorting out your diag-

nosis and repair problems.TD

3

4

5

Lift pump with slots for bleed-off cut at 10and 2 oclock positions

Lift pump before cutting of slots

Lift pump assembled to show depth of bleed-

off slots


38/68


Identifying the 5L40-E and 5L50-ETransmissions and Valve Bodies

The 5L40-E and 5L50-E transmissions and valvebodies look the same at a glance. On theCadillac, Pontiac Solstice and Saturn Sky, you

can look on the service-parts identification label toidentify the transmission by the RPO (RegularProduction Options) number.

To identify thetransmission, findthe identification tag(Figure 1) attached tothe transmission caseat the left rear justabove the pan rail.The 5L50-E was usedin Cadillac vehiclesonly with the 4.6-liter engine.

To identify the

transmission in aBMW, look for a G orZ on the tag in the lo-cation shown in Figure 1. BMW also refers to the5L40-E as an A5S 360R.

When you are trying to identify a 5L40-E/5L50-Evalve body, look for the three-digit separator-platecode (Figure 2) and the casting number on the second-accumulator housing. The 5L50-E will have a three-digit separator-plate number of 374. The castingnumber on the 5L50-Es second-accumulator housingis 96023532 (Figure 3), and this is the only accumula-

tor that has inner and outer springs. The 5L40-E does

NOT use the 374 plate or the 96023532 second accu-mulator.

One other difference in the 5L50-E valve body isthe size of the TCC regulator apply valve behind theTCC solenoid. In the 5L50-E, the valve is the same di-ameter at both the inner and outer lands, 0.4755 inch.

The 5L40-E TCC regulator apply valve has an inner-land diameter of 0.436 inch and an outer-land diame-ter of 0.510 inch.

General Motors and BMW do not sell the accumu-lator springs or housings separately. That means thatthey do not supply identification information forthese parts. This valve body has four accumulatorsthat can bolt onto any one of four spots. That wouldbe OK if all the accumulators were the same.

2

Subject:

Identifying transmissionsand valve bodies

Author:

Jeff Parlee

Unit:

5L40-E, 5L50-E


Cadillac, Pontiac Solstice,Saturn Sky, BMW

TECHNICAL

TRAINING

Body Of Evidence

Essential Reading:

Rebuilder

Shop Owner

Center Manager

Diagnostician

R & R

Manufacturer Transmission RPO # RWD/AWD Location of Service-PartsID Label

Cadillac 5L40-E MX5 AWD Under spare-tire cover

Cadillac 5L40-E M82 RWD Under spare-tire cover

Cadillac 5L50-E MV3 AWD Under spare-tire cover

Cadillac 5L50-E M22 RWD Under spare-tire cover

Saturn Sky 5L40-E M82 RWD Inside glove box

Pontiac Solstice 5L40-E M82 RWD Inside glove box*

* On 2006 Pontiac Solstice only, the service-parts ID label is under the spare-tirecover.

3-digitplatecode

TCCsolenoid

1

5L40-E/5L50-E identification plate

5L40-E = G5L50-E = Z Year

9 6 0 2 4 2 3 7

3

GXG 3

The castingnumber of the5L50-Es secondaccumulator ison top of theaccumulatorhousing.

continues page 38


39/68

Timely

Transmission Tech/Talkdelivers answers and updatesfor an unending variety of transmission systems.Answers for the units youre just starting to see andupdates for transmissions that youve been seeingfor years. Hydraulics, electronics, mechatronics andmore.

oncise

Transmission Tech/Talk is not a textbook nor a ram-bling collection of long-winded articles. Tech/Talk isfor transmission professionals who need currentinformation that doesnt take all day to read. TheComplaint - Cause - Correction format has madeTech/Talk a favorite of the transmission repair pro-fessional for many years.

ffordable

Transmission Tech/Talknewsletter is an unbelievablebargain. Theres nothing else to purchase and no

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A u t o m o t i v e T e c h n i c a l N e w s l e t t e r s


40/68


Body Of Evidence

SecondAccumulator

IntermediateAccumulator

OverdriveAccumulator

DirectAccumulator

Top of Acc. I.D. 1.173 in. 1.340 in. 1.340 in. 1.340 in.

Bottom of Acc.

I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020761 96021042 96021042 96021042

Spring freelength

2.184 in. 2.250 in. 2.250 in. 2.250 in.

Spring wiredia.

0.076 in. 0.088 in. 0.088 in. 0.088 in.

Spring color Yellow Lt. blue Lt. blue Lt. blue

# of springcoils

10 10 10 10

Spring O.D. 0.727 in. 0.730 in. 0.730 in. 0.730 in.

3-digit platecode

066

SecondAccumulator



DirectAccumulator

Top of Acc. I.D. 1.280 in. 1.340 in. 1.340 in. 1.340 in.

Bottom of Acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020762 96021042 96021042 96021042

Spring freelength

2.245 in. 2.260 in. 2.260 in. 2.260 in.

Spring wiredia.

0.085 in. 0.085 in. 0.085 in. 0.085 in.

Spring color Plain Plain Plain Plain

# of springcoils

10 10 10 10


3-digit platecode

008

Unfortunately, there are five different sizes, and theydont always go in the same spot on every valve body.Each accumulator has at least one spring, sometimestwo, and the springs are not all the same. If theseparts are not marked or tagged during disassembly itcan be a real challenge to reassemble this valve bodycorrectly. See Figure 4 for accumulator identification.

The information supplied in the following tablesshould help you assemble these parts in the correct lo-cation and avoid shift-feel problems. Just find thetable that has the plate code, accumulator-cover num-bers and springs that match your parts. TD

4

SSC

TCC

EPCSSB

SSA

2ndaccumulator

Overdriveaccumulator

Intermediateaccumulator

Directaccumulator

5L50-ECadillac Second Accumulator Intermediate

AccumulatorOverdrive

AccumulatorDirect

AccumulatorOuterspring

Innerspring

Top ofacc. I.D.

1.173 in. 1.281 in. 1.281 in.

Bottomof acc.

I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc.housing

#

96023532 96020761 96020762 96020762

Spring

freelength

2.650 in. 1.611 in. 2.410 in. 2.220 in. 2.410 in.

Springwire dia.

0.088 in. 0.088 in. 0.093 in. 0.089 in. 0.093 in.

Springcolor

White Plain Plain White Plain

# ofspringcoils

9 6 10.5 10 10.5

SpringO.D.

0.737 in. 0.473 in. 0.737 in. 0.735 in. 0.737 in.

3-digitplatecode

374

5L40-ESecond

AccumulatorIntermediateAccumulator


DirectAccumulator

Top of acc.I.D.

1.280 in. 1.340 in. 1.340 in. 1.340 in.

Bottom ofacc. I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing#

96020762 96021042 96021042 96021042

Spring freelength

2.250 in. 2.250 in. 2.250 in. 2.250 in.

Spring wiredia.

0.090 in. 0.090 in. 0.090 in. 0.090 in.

Spring color Lt. green Lt. green Lt. green Lt. green

# of springcoils

10 10 10 10


3-digit platecode

008


41/68

February 2012 39

SecondAccumulator



DirectAccumulator

Top of acc. I.D. 1.280 in. 1.280 in. 1.418 in. 1.340 in.

Bottom of acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020762 96020762 96022005 96021042

Spring free

length

2.405 in. 2.225 in. 2.35 in. 2.35 in.

Spring color Plain Lt. blue Orange Orange


Spring wiredia.

0.094 in. 0.091 in. 0.082 in. 0.082 in.

# of Coils 11 10 10 10

3-Digit plateCode

068

continues next page

Schaeffler Group USA Inc. Wegman Dr.Valley City, OH Tl: ..Tlc: ..www.Schaeffler-Aftermarket.us

Think Inside The Box!

Trust the quality of LuK.Trust the yellow box.

These days, it seems that everyone is telling you to

think outside the box. When it comes to clutch

replacement, thats just not good advice. Many clutch

marketers mix and match parts from various sources, a

practice that creates quality and installation problems.

The parts may bolt up, but can fail prematurely,

resulting in a comeback for you. When you install a LuK

RepSet, you get the same flawless performance as the

original equipment parts.

Designed and engineered to work together. Why risk

your time and reputation with anything else?

Certified toISO :

SecondAccumulator



DirectAccumulator


Bottom of acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020761 96021042 96022005 96021042

Spring freelength

2.560 in. 2.221 in. 2.320 2.228 in.

Spring wiredia.

0.094 in. 0.090 in. 0.082 in. 0.090 in.

Spring color Blue White Orange Plain

# of springcoils

11 10 10 10


3-digit platecode

378

Second

Accumulator

Intermediate

Accumulator

Overdrive

Accumulator

Direct

Accumulator


Bottom of acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020762 96020762 96022005 96022005

Spring freelength

2.370 in. 2.370 in. 2.330 in. 2.330 in.

Spring wiredia.

0.090 in. 0.090 in. 0.080 in. 0.080 in.

Spring color Plain Plain Orange Orange

# of spring

coils

11 11 10 10


3-digit platecode

275


42/68


Body Of Evidence

SecondAccumulator



DirectAccumulator


Bottom of acc.

I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020762 96021042 96021042 96022005

Spring freelength

2.390 in. 2.250 in. 2.250 in. 2.220 in.

Spring wiredia.

0.093 in. 0.090 in. 0.090 in. 0.080 in.

Spring color Plain Lt. green Lt. green Yellow

# of springcoils

11 10 10 10


3-Digit plateCode

789

SecondAccumulator



DirectAccumulator


Bottom of acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020762 96021042 96022005 96021042

Spring freelength

2.390 in. 2.240 in. 2.230 in. 2.240 in.

Spring wiredia.

0.093 in. 0.090 in. 0.080 in. 0.090 in.

Spring color Plain White Yellow White

# of springcoils

11 10 10 10


3-digit platecode

789

SecondAccumulator



DirectAccumulator


Bottom of acc.I.D.

1.654 in. 1.654 in. 1.654 in. 1.654 in.

Acc. housing # 96020761 96020761 96020762 96021042

Spring freelength

2.565 in. 2.365 in. 2.230 in. 2.365 in.

Spring color Lt. blue Plain Lt. blue Plain


Spring wiredia.

0.095 in. 0.093 in. 0.091 in. 0.093 in.

# of Coils 10.5 10.5 10 10.5

3-digit platecode

614

SecondAccumulator



DirectAccumulator


Bottom of acc.

Trans Digest 12

Documents

Transcript of Trans Digest 12