Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ OBJECTIVES After studying Chapter 18, the reader should be able to: 1.Disassemble and reassemble automatic transmission subassemblies. 2.Determine if used subassemblies and their components are usable. 3.Complete the ASE tasks related to off-vehicle transmission/transaxle repair.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ SUBASSEMBLY REPAIR Inspection, service, and repair operations are done to each of the transmission subassemblies as part of the transmission overhaul. These subassemblies include the case, pump, clutch assemblies, gearset, valve body, and governor. Subassembly repair ensures that each component is serviceable and will work properly when the transmission is assembled.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CASE INSPECTION Several areas of the case should be checked or serviced after it has been cleaned. These include the bushings, all fluid passages, the valve body worm tracks (grooves for the valve body fluid flow), all bolt threads, the clutch plate lugs, and the governor bore.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CASE INSPECTION FIGURE 18-1 This tool is designed to attach to the rear of an E4OD or C6 case. It guides a reamer that will cut the damaged bore to a larger diameter; an oversized bushing is then used to repair the case and a more durable bushing is installed. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Some technicians draw file the valve body area using a 16-in., single-cut file as standard practice. To draw file a case, place the case with the worm tracks upward, lay the file flat, grip each end of the file, and draw the file sideways across the case. FIGURE 18-2 A flat, smooth file is being drawn (moved in the direction of the arrow) across the valve body area of a case to smooth out any dings or warpage.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP If a low-mileage transmission has failed because of a burned clutch or band you should check for pressure loss and cross leaks. FIGURE 18-3 This worm track (arrow) has been closed off and filled with ATF to check for a suspected leak (a). The low-reverse clutch failed because of a pressure loss through a crack (circled) (b). It was found by watching ATF leak out of the crack.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CASE INSPECTION FIGURE 18-4 This case shows wear in the area where the lowreverse clutch plates contact the lugs. This case is still usable, but excessive wear might hamper proper clutch apply and release.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP The governor bore size can be checked by placing the governor into its bore and filling the passages with ATF. FIGURE 18-5 Governor bore wear is checked by placing the case on its back (a); inserting the test tool into the governor bore (b); filling the passage with ATF (c); and seeing how long it takes for the fluid to leak down to point A. (b is courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Minor scores in a governor bore can be cleaned using a small cylinder hone. FIGURE 18-6 A small cylinder hone dipped in ATF can be used to smooth out minor scores in a governor bore. It should be turned by hand. Power tools should not be used.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Some transmissions develop a fluid leak around the shift shaft because of a worn bore. A repair kit has been developed that includes a reamer, reamer guide, repair sleeve, and retaining pins FIGURE 18-7 An A4LD tends to wear the manual shift linkage bore and leak fluid. The case can be repaired by reaming the bore oversize and installing a repair sleeve. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Some accumulator bores tend to wear because of repeated accumulator piston oscillation. FIGURE 18-8 A damaged or worn accumulator bore can be repaired by installing a sleeve and a matching piston. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CASE INSPECTION FIGURE 18-9 The manual valve shaft seal is driven into place using a seal driver.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE Service of most pumps consists of the following: –Disassembly –Inspection of the pumping members, stator support shaft, front bushing, clutch support surface, and sealing ring grooves –Checking of all valves –Cleaning of all fluid passages, including the drainback hole –Replacement of the front seal –Reassembly

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE The pump gears and their cavity are carefully checked for wear and the front seal is normally replaced. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE The rotor and slide of this vane pump are broken (a) and the pump body (b) is badly scored. This pump must be replaced.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE Clearance checks of the pump gears include end clearance (a), gear-to-housing clearance (b), and gear-tooth clearance (c). (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE An exploded view of a vane-type pump. Wear checks include the rotor, vanes, slide, pump body, and pump cover.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE If replacement is needed for the pump rotor (a), vanes (b), or slide (c), they should be measured to determine the proper size. (Reprinted with permission of General Motors)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE A new front seal is being installed using a seal driver (SST).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE A replacement stator support shaft for a 4L60 transmission that uses a set screw to prevent rotation of the inner sleeve. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Metal caged lip seals are not designed to retain pressure. The fluid that is fed to lubricate the front bushing normally drains back into the transmission case through a drainback hole between the bushing and the seal. FIGURE Fluid flowing through the pump bushing must be allowed to flow to the pan through the drainback passage. If this passage is blocked, a drill bit of the proper size should be used to clean it out. (Reprinted with permission of General Motors)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE These special tools are used to align the pump gears of certain Ford transmissions while the bolts are tightened. (Courtesy of ATEC Trans-Tool and Cleaning Systems)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ PUMP SERVICE FIGURE Special tool J is being used to align the pump body and cover before tightening the bolts (a). A long screw clamp can be used for this same purpose (b). (a is reprinted with permission of General Motors)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP An alternate aligning method is to place the pump upside down in an empty transmission case before tightening the bolts. FIGURE The pump body and cover can be aligned correctly by placing them into the case upside down while the bolts are tightened.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE The service procedure for most clutch assemblies is as follows: –Remove the clutch plates and disassemble the return spring(s) and piston. –Thoroughly clean the parts. –Inspect the drum, piston, and check ball as well as the bushing and seal ring area. –Install new seals on the piston. –Install the piston and return spring(s). –Install the clutch plates. –Check the clutch clearance.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE An exploded view of a clutch assembly; note the clutch stack with four frictions and the strong piston spring. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE The large snap ring can usually be removed using a screwdriver or seal pick (a) and then the pressure plate and clutch plates can be removed (b).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE This variety of clutch spring compressors includes completely portable ones (a, b, and c), a bench-mounted style (d), and a large, foot- operated style (e). (a, left, is courtesy of Chrysler Corporation; a, right, is courtesy of Kent-Moore; b is courtesy of OTC; d and e are courtesy of KD Tools)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE (CONTINUED) This variety of clutch spring compressors includes completely portable ones (a, b, and c), a bench-mounted style (d), and a large, foot- operated style (e). (a, left, is courtesy of Chrysler Corporation; a, right, is courtesy of Kent-Moore; b is courtesy of OTC; d and e are courtesy of KD Tools)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP While the return springs are being removed, be sure to note the number and location of the springs if all of the pockets are not filled with springs. FIGURE Some clutch assemblies do not use a spring in each of the pockets. Note how they are arranged in this clutch. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE A piston can be removed by slamming the clutch downward on a block of wood (a) or applying air pressure in the apply port (b).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE This piston is made from stamped steel parts that can separate. It is tested by inserting a screwdriver and trying to pry the grooves open with a light pressure.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE The check ball should be free to move inside its cage. It should also seal low-pressure air flow in one direction (left) and leak in the other (right).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE This bushing appears usable and the two sealing ring areas (arrows) show normal operation.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE This rear clutch stack has a selective snap ring, top pressure plate, four friction disks, three steel plates, bottom pressure plate, and wave spring to retain the Belleville piston spring. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Always check to be sure the plates turn freely with the clutch released. FIGURE With the clutch assembled and lying flat, you should feel a definite drag if you try to rotate the plates (left). The plates should rotate easily with the clutch vertical (right).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE FIGURE The clutch pack clearance specification for this clutch is to in.(0.64 to 1.14 mm). A in.feeler gauge should enter as shown, but a in. feeler gauge should be very tight or not fit in at all. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Clearance can also be measured using a dial indicator. FIGURE A dial indicator can be set up with the stylus on the piston to measure piston stroke (a). Applying air to the proper passage should cause the piston to stroke so the travel can be measured (b).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE This reaction clutch is deep in the case, and the clearance is measured by lifting a clutch plate while watching the dial indicator (a). Clutch clearance is adjusted by selecting the proper reaction/pressure plate (b). (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE This clutch pack is assembled and the height is measured. The height should be within the specified dimensions.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP If the selective parts do not correct the clearance or are not available, clutch clearance can be reduced by using extra-thick steel plates or adding an extra unlined steel or lined friction plate. FIGURE Clutch clearance can be reduced by adding an extra unlined plate (a and b) or lined plate (c). If two lined plates are next to each other as in c, clearance can be increased by shaving the lining off one or both adjacent sides of the two lined plates.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Most technicians air check a clutch as soon as it is assembled. When air pressure is applied to the clutch, the piston should stroke, squeeze the clutch together, and not leak FIGURE Air pressure is applied to the shaft clutch apply port (a) to apply and air test the clutch piston. The amount of piston stroke and clutch pack clearance are measured using a dial indicator. The special service tool (SST) allows the dial indicator to reach the piston. (b courtesy of Toyota Motor Sales USA, Inc.)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CLUTCH ASSEMBLY SERVICE One-Way Clutch Service –One-way clutches are visually inspected during transmission disassembly and reassembly (see Section 16.6). –The commonly encountered problems are: severe wear from poor lubrication or metal fragments from a failed part; wear or scoring of the race(s), rollers, or sprags; and a sprag(s) that flips over. –One-way clutches should always be lubricated using assembly grease, petroleum jelly, or ATF during assembly.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE Servicing gearsets is primarily a visual inspection of the various gears and a side play and rotation check of the planet gears. In some cases there is also an end-play check of the assembled gear train to ensure the thrust washers are not worn excessively. FIGURE This gearset should have to in. (0.12 to 1.22 mm) of end play. A in. feeler gauge should enter as shown, but a in.gauge should not. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE This kit includes the parts needed to rebuild a 4L60 planetary assembly. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE Planetary gear train damage shows up as wear (a–d) or cracks and breakage (e).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE (CONTINUED) Planetary gear train damage shows up as wear (a–d) or cracks and breakage (e).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE These three gear train components show severe wear and scoring in the thrust surfaces.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE These sun gear drive shells show stripped splines (a) and broken, dislodged splines (b).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ GEARSET SERVICE FIGURE This planet pinion gear has too much side clearance; it should be repaired or the carrier should be replaced.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE Despite its complexity, the valve body is one of the more reliable parts in a transmission, probably because the valves are so well lubricated. In a way, valves do little, as they move only slightly and only once in a while. Most valve body service operations consist of disassembly, cleaning, checking for free movement, reassembly, and in a few transmissions, adjusting the pressure regulator valve

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE An exploded (a) and cutaway (b) view of the valve body from a four-speed transaxle. Note the various valve groups and how they are retained in their bore.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE (CONTINUED) An exploded (a) and cutaway (b) view of the valve body from a four-speed transaxle. Note the various valve groups and how they are retained in their bore.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP Some technicians make a valve organizer by folding a piece of cardboard into an accordion shape. FIGURE A sheet of stiff paper has been folded to create this simple valve holder. Note that a valve group can be placed in order and also labeled.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE This simple shop-made tool is a valve body spring holder. It is made from two electrical box covers, a 1/4 in. x 2-1/2 in. stove bolt and nut, and 16,8 x 2 in. machine screws and nuts. As a valve is removed, the spring is placed over a numbered peg, and the number is written on a picture of the valve body.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE These valves are retained by two cover plates; with the covers removed, the valves should slide out of their bores. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE These valves are held in the valve body by a plug and a pin or retainer. (Courtesy of Toyota Motor Sales USA, Inc.)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE A drill bit (a) or Allen wrench (b) can be modified so that it enters a roll pin, and then is rotated to lift the pin out. (Reprinted with permission of General Motors)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE If the valve body is moved to vertical position, steel valves should slide freely from the bore. Be prepared to catch the valves when making this check.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE A valve sag test (a); the valve is inserted backwards into the bore so the inner land is in the area where it normally runs. The valve should not sag off- center. This aluminum valve body has been cut to show the ridges that indicate bore wear (b). Some valve bodies can be saved by reaming the bore oversize and installing an oversize valve (c). (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE This valve body is being washed and air dried in a parts washer. It will be cleaned again when the two major parts are separated.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE Place the valve on the wet sharpening stone and rotate the valve. Slight imperfections and burrs can be removed without rounding off the sharp edges. Do not do this with aluminum valves.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE Sometimes a valve in an aluminum valve body will stick in its bore because of grit embedded in the bore wall. This valve can often be freed by gently striking the valve as shown.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE A scored valve body bore can be cleaned by inserting a small roll of crocus cloth into the bore and rotating it in a direction to unroll it. Be very careful to not remove any metal and cause an oversize bore when cleaning the bore of an aluminum valve body.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP FIGURE A wire handle has been attached to an old valve so it can be used to lap a governor bore (a). A mixture of scouring powder and ATF is used for the lapping compound (b).

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE This boost valve can be checked by putting a small amount of ATF into the EPC boost and D2, low passages and applying low-pressure air to the same passages. More than minimal leakage through the cutback and other passages indicate a worn boost valve or boost sleeve. (Courtesy of Sonnax)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE This valve body contains one large and six small check balls. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE The valve body bolts should be tightened in order, starting from the center and working in an outward spiral.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ TECH TIP If a faulty check ball– transfer plate seat is suspected, place the ball on its seat and hold a flashlight behind the transfer plate. Light shining between the ball and transfer plate indicates a problem. FIGURE A check ball should seal off light from coming through the spacer plate. A problem is indicated if light shines through an opening alongside of the check ball.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ VALVE BODY SERVICE FIGURE The pressure regulator spring of this valve body should be adjusted to 1-5/16 in. to get the proper line pressure. (Courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ SOLENOIDS AND SWITCHES Some sources recommend replacing all switches and solenoids to eliminate a possible cause of future problems. A pulse-width solenoid or pressure control solenoid is in almost constant motion while the transmission is operating; these units wear out. Any external switch that leaks fluid should be replaced.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ DIFFERENTIAL SERVICE Transaxle differentials should be checked to make sure that the differential gears, thrust washers, and the differential pinion shaft are in good condition. FIGURE Differential side gear end play can be checked using a dial indicator and special tool (a). Another check for the same purpose is to measure the side gear backlash (b). (a is courtesy of Chrysler Corporation)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ DIFFERENTIAL SERVICE FIGURE Removing the pinion shaft allows the differential pinion and side gears with their thrust washers to be removed from the differential case. (Courtesy of Toyota Motor Sales USA, Inc.)

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ SUMMARY 1.Inspection, service, and repair are done to each transmission subassembly during the transmission overhaul. 2.The pump is disassembled and inspected. The bushings and seals are replaced before reassembly. 3.When rebuilding a clutch, the friction plates, piston seals, and bushings are replaced. 4.The valve body is disassembled, cleaned, inspected, and carefully reassembled.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ REVIEW QUESTIONS 1.The areas of the case that should be inspected are: a.______ b.______ c.______ d.______ e.______ f.______ 2.The pump should be inspected for _________ marks and damage to the gears and housing. 3.When assembling a pump, it might be necessary to _________ the pump halves before torquing the pump body bolts. 4.Like a gear pump, a vane-type pump should be _________ inspected. 5.When disassembling a clutch assembly, note the location of any _________ plates and the _________ and order of the clutch friction and steel plates.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ REVIEW QUESTIONS 6.Transmission gearsets are inspected for _________ to the gears and pinion gear _________. 7.Valve body repair consists mainly of disassembly, _________, and reassembly. 8.When cleaning a valve body, all of the parts must be kept in _________. 9.Any external switch that is leaking should be _________. 10.If differential clearance is excessive, replace the _________ Washers.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 1.Student A says that a cross leak can cause damage to the clutches or bands. Student B says that damage that would cause a cross leak can be checked using a feeler gauge and a straightedge. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 1.Student A says that a cross leak can cause damage to the clutches or bands. Student B says that damage that would cause a cross leak can be checked using a feeler gauge and a straightedge. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 2.Student A says that aluminum on the thread of a bolt indicates that the threads in the case are damaged. Student B says that all bolts should be checked for damage before they are reused. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 2.Student A says that aluminum on the thread of a bolt indicates that the threads in the case are damaged. Student B says that all bolts should be checked for damage before they are reused. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 3.Student A says that a pump can be checked with a visual check or by measuring the clearances. Student B says that worn pump bushing will result in a leaking pump seal. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 3.Student A says that a pump can be checked with a visual check or by measuring the clearances. Student B says that worn pump bushing will result in a leaking pump seal. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 4.Student A says that it is good practice to replace all of the friction materials (lined plates, unlined plates, and bands) when rebuilding a transmission. Student B says that lined friction material must be soaked in ATF before it is installed. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 4.Student A says that it is good practice to replace all of the friction materials (lined plates, unlined plates, and bands) when rebuilding a transmission. Student B says that lined friction material must be soaked in ATF before it is installed. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 5.Student A says that the location and number of springs in the clutch pack should be noted and that the same number of springs must be placed in the same location during reassembly. Student B says that a clutch piston can be removed with air pressure or by tapping the clutch housing on a piece of wood. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 5.Student A says that the location and number of springs in the clutch pack should be noted and that the same number of springs must be placed in the same location during reassembly. Student B says that a clutch piston can be removed with air pressure or by tapping the clutch housing on a piece of wood. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 6.Student A says that the check ball in the clutch piston should rattle when shaken. Student B says that it is okay if the check ball has a small fluid leak. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 6.Student A says that the check ball in the clutch piston should rattle when shaken. Student B says that it is okay if the check ball has a small fluid leak. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 7.Clearance in a multiple-disc clutch is adjusted using any of these selective parts, except a)clutch pressure plates. b)clutch housings. c)pressure plate snap rings. d)steel plates.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 7.Clearance in a multiple-disc clutch is adjusted using any of these selective parts, except a)clutch pressure plates. b)clutch housings. c)pressure plate snap rings. d)steel plates.

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 8.Student A says that the gearset is visually inspected for wear or damage to the gear teeth. Student B says that the planet pinion gear end play should be checked using a feeler gauge. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 8.Student A says that the gearset is visually inspected for wear or damage to the gear teeth. Student B says that the planet pinion gear end play should be checked using a feeler gauge. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 9.Student A says that the valve and springs must be kept in order during valve body service. Student B says that the valve body springs should be checked for damaged or distorted coils. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 9.Student A says that the valve and springs must be kept in order during valve body service. Student B says that the valve body springs should be checked for damaged or distorted coils. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 10.Student A says that during an overhaul of a transaxle, the differential should be disassembled and inspected. Student B says that the differential is not a part of the automatic transaxle. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B

Automatic Transmissions and Transaxles, Fourth Edition By Tom Birch and Chuck Rockwood © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ CHAPTER QUIZ 10.Student A says that during an overhaul of a transaxle, the differential should be disassembled and inspected. Student B says that the differential is not a part of the automatic transaxle. Who is correct? a)Student A b)Student B c)Both A and B d)Neither A nor B