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Intro i

TECHNICAL
SEMINAR

© 2010 ATRA. All Rights Reserved.


ii Intro
TECHNICAL RESOURCES AUTOMATIC TRANSMISSION
Access to the automotive industry’s master REBUILDERS ASSOCIATION

great
technicians by phone, fax, email, Internet and
live chat! Plus, ATRA Members receive a discount
off the cost of all bookstore sales.

reasons
BUSINESS SUPPORT
Learn the industry’s trends and business success
through the ATRA’s on-going What’s Working
study.

NATIONWIDE WARRANTY
ATRA’s Golden Rule Warranty is an inter-shop
warranty plan that ATRA Rebuilder Members may to join
ATRA
offer the motoring public. Build trust with your
customers by providing a nationwide warranty.

CONSUMER REFERRALS
Consumers sent to your shop through the ATRA
Shop Finder search page online. ATRA’s shop
finder receives more than 5,000 consumer
searches every month.

NETWORKING GROUPS
Have questions about tech? Business
operations? Want to network with successful
industry leaders? ATRA’s forums are available for
discussion topics about management, tech and
industry news.

EVENTS DISCOUNTS
ATRA members receive substantial discounts for
ATRA Technical seminars and conferences.

CERTIFICATION
ATRA encourages technical competency and a
high standard of professionalism with it’s own
certification program, FREE to all members.

BENEFIT PROVIDERS
ATRA partners with a selective group of
respected companies, like Citibank and FedEx to
expand the value of your membership with
valuable discounts on products and services you
already use.

The Automatic Transmission Rebuilders Association is your resource for tech support, business support, education,
networking, and more. Join today by logging on at www.atra.com and get connected with your industry!

Call the Membership Department at 805.604.2000 or email membership@atra.com, if you have any questions.

www.atra.com | 805.604.2000

© 2010 ATRA. All Rights Reserved.


Intro iii

The
Automatic Transmission Rebuilders
Association
2400 Latigo Avenue
Oxnard, CA 93030
Phone: (805) 604-2000 Fax: (805) 604-2005
http://www.atra.com
This manual has been developed by the Automatic Transmission Rebuilders Association
(ATRA) Technical Department to be used by qualified transmission technicians in
conjunction with ATRA’s technical seminars. Since the circumstances of its use are
beyond ATRA’s control, ATRA assumes no liability for the use of such information or any
damages incurred through its use and application. Nothing contained in this manual is
to be considered contractual or providing some form of warranty on the part of ATRA. No
part of this program should be construed as recommending any procedure which is
contrary to any vehicle manufacturer’s recommendations. ATRA recommends only
qualified transmission technicians perform the procedures in this manual.

This manual contains copyrighted material belonging to ATRA. No part of this manual
may be reproduced or used in any form or by any means — graphic, electronic or
mechanical, including photocopying, recording, electronic or information storage and
retrieval — without express written permission from the ATRA Board of Directors.
Public exhibition or use of this material for group training or as part of a school
curriculum, without express written permission from the ATRA Board of Directors is
strictly prohibited.

ATRA and the ATRA logo are registered trademarks of the Automatic Transmission
Rebuilders Association.

Portions of materials contained herein have been reprinted with permission of General
Motors Corporation, Service Technology Group Agreement # 0610228.

Portions of materials contained herein have been reprinted with permission of Ford
Motor Company.

Portions of materials contained herein have been reprinted with permission of Daimler
Chrysler Corporation.

© 2010 ATRA. All Rights Reserved.


iv Intro

© 2010 ATRA. All Rights Reserved.


Intro v

Lance Wiggins
Technical Director
Congratulations on attending ATRA’s 2010 Technical Seminar!
These days, many shops are devoting more of their time to learning marketing and
management techniques; concepts and practices designed to help shops bring more
customers in the door.

That’s important — we can’t stay in business without customers. But bringing ’em in the
door is only half the job: It doesn’t mean a thing unless you have the skills and training
to get ’em back out again.

That’s what the ATRA Technical Seminar program is all about: It’s designed to provide you
with the latest information and training, to help you fix today’s transmission problems. So
you can get ’em out the door again, with their transmissions working like new. Because
that’s what’ll keep ’em coming back… again and again.

So, on behalf of the ATRA staff and the ATRA Chapters that have worked so hard to put
this program together, I’d like to welcome you, and thank you for doing your part to keep
our industry strong. We hope you have a wonderful day, and a terrific learning
experience.

Lance Wiggins
ATRA Technical Director

© 2010 ATRA. All Rights Reserved.


vi Intro

Already in the Future!

è Company Profile & Product Features ç


Automatic Transmission Related
OEM to GM & Ford in
Wet Friction & Torque
Converter Products.
From the world’s largest independent manufacturer of torque converters and
the world’s largest manufacturer of combined wet and dry friction products.

Exedy dominates the OEM


market in the world over-fact! CORE TECHNOLOGY
Exedy is a powertrain specialist and tier one supplier FRICTION
to the automotive industry world wide. Exedy’s Development of ç
products range: From wet & dry friction material, torque the highest quality
FRICTION MATERIAL
converters, complete transmission systems for highway,
off-highway and industrial applications.
that can demonstrate
the World’s top level =FRICTION TECHNOLOGY
performance
Exedy is responsible to all 11 OE automotive vehicle
manufacturers in Japan. For the conception of
powertrain product requirements and needs. ç
VIBRATION
In the US Exedy supplies Ford-GM-Chrysler, powertrain We have
needs such as torque converters, wet friction material
=DAMPER TECHNOLOGY
developed the most
and standard clutch systems. efficient Damper that
can absorb vibration
Worldwide Exedy has evolved through developing from the engine
and patenting the core technologies such as friction, FLUID more than ever.
vibration and fluid technology. DYNAMICS
Having analyzed
ç
Exedy products have been recognized by vehicle the fluid dynamics

=FLUID TECHNOLOGY
inside Torque Converter,
manufacturers all over the world. As a premium brand EXEDY has successfully
in Japan, Exedy products are valued so highly that developed the most
our products are renowned all over the world by car efficient product in
manufactures. Exedy continues to hold a large share of the market
Excellent Capacity for
the OEM market both domestically and internationally.
Development for Fluid Technics

www.exedyusa.com
Available through all authorized Transmission WDs & Jobber Shops
© 2010 ATRA. All Rights Reserved.
Intro vii

ATRA Staff

Chief Executive Officer: Dennis Madden


GEARS Managing Editor: Rodger Bland
GEARS Magazine: Frank Pasley
Jeanette Troub

Events Manager: Vanessa Velasquez
Event Services: Kim Paris

Director of Membership
and IT Services: Kelly Hilmer
Membership Department: Kim Brattin
Deon Olmos
Jim Spitsen

Accounting Manager: Jody Wintermute
Accounting Department: Rosa Smith
Valerie Mitchell

Bookstore Manager: Ron Brattin
ATRA Technical Department: Lance Wiggins, Technical Director
Shaun Velasquez, Project Manager
Randall Schroeder, Senior Technician
Mike Souza, Senior Technician
Bill Brayton, Senior Research Technician
Pete Huscher, Technical Advisor
Mike Brown, Technical Advisor
Jon Rodriguez, Technical Advisor

© 2010 ATRA. All Rights Reserved.


Table of Contents
Ford 69
Ford
AWF-21B
Harsh, Erratic or Slow Downshifts/Upshifts..............71
AX4S/AX4N
Erratic Shifts or Shuttle Shifting................................72
4F50N
Erratic Tranmission and Engine Operation................73
4F50N/AX4S/AX4N
1-2 or 2-3 Flare Shift.................................................74
6F50N
No Reverse, 3rd or 5th Gears.....................................75
PCM Reflashes for Various Concerns.........................76
4R100
No Upshift.................................................................77
Torqshift
Dummy Pressure Switches........................................78
High or Erratic Line Pressure.....................................79
5R55N/W/S
Oil Fill Procedures.....................................................80
Harsh 2-3 Shifts........................................................83
4R100, 4R70W w/ Transfer Case
Erratic Speedometer Reading.....................................85
Chatter Type Noise....................................................86
4R70W/E and 4R75E
Low Speed Tie-up......................................................87
Falling Out of Gear at a Stop.....................................88

© 2010 ATRA. All Rights Reserved.


70 Ford
AL- Birmingham GA - Atlanta NC - Charlotte PA - Scranton
Florence KY - Louisville IN - Evansville TN - Knoxville
CO- Denver MS - Jackson Indianapolis Nashville
FL - Ft. Lauderdale MN - Minneapolis OH - Cincinnati TX - Dallas
Orlando MO - St. Louis Dayton Fort Worth 800-940-0197
Tampa OK - Tulsa Buy on Line @ wittrans.com

Company Profile Products


Whatever It Takes (WIT) was Whatever It Takes carries
founded in 1999 by Kenny top-quality products from
Hester, a 30-year veteran in manufacturers such as
the Transmission parts supply Raybestos, Toledo
business. WIT is the complete Trans-Kits, Allomatic,
source for all its customer’s ATEC-Transtool, ATSG,
transmission parts needs, Autocraft Manufacturing,
whether it is new, used, or remanufactured. Parts are Borg Warner, CVC Torque Converters, DT Components,
currently distributed by 22 branch locations Hayden Coolers, Life Automotive, Lubegard, Powertrain
throughout the U.S. With the main remanufacturing and Systems, Precision International, Rostra, Sachs Clutch Kits,
distribution located within 10 minutes of U.P.S.’ major Air Sonnax, SPX Filtran, Stellar Group, Superior, Teckpak-Fitzall,
Hub, Whatever It Takes is able to quickly ship parts Transgo, Tri- Components, TTXE, Valeo Clutch Kits,
worldwide. The majority of the sales staff have been in Zoom Technology, OE manufacturers and many others.
the business for over 18 years. WIT is an employee owned, In addition to new O.E. parts, W.I.T. also carries a full line
customer driven company, there are no stockholders or of remanufactured and used parts for both Automatic &
investors to report to. As owners, the WIT employees’ only Standard transmission. W.I.T. remanufactures Standard
job is to provide the customer with the things they need transmissions & transfer cases that include a 12 month/
to be the most successful shop possible. unlimited mile warranty against parts and workmanship.*

Customer Service Research & Development


Customer Service is the cornerstone that W.I.T. was The Research & Development team stays current with the
founded on, and has helped it become a major competitor latest transmissions & take photos of every part in these
in the transmission parts business. Whatever It Takes transmissions in order to
prides itself on its excellent customer service and having provide most complete Ve s n 2 5
n l d s r nn Gu e
o mo t a s h u
he 7 M de Y ar

the parts you need by maintaining a minimum fill rate of transmission catalog in the
2007
2 07

20
07 © nc
Wh te e t akes

98.8%. W.I.T. prides itself on taking care of its customers. industry. They gather
Service, Experience, Quality, Product Availability, Timely information on common
Credits, a dedicated Customer Service line are just a few of wear issues with each new
2007
2 07 2007
2 07

the reasons why Whatever It Takes has become a major transmission, and develop text descriptions for all the
competitor in the transmission parts business. WIT is able Catalogs and WIT’s website (www.wittrans.com). The R & D
to ship its parts overnight to most of the North and South team was responsible for creating W.I.T.’s Catalog CD with
Eastern U.S. With its strategically placed stores, it is point and click technology, The Award winning & most
possible for WIT to service about 80 % of the country up-to-date Vehicle to Automatic Transmission Guide in the
within 2 days. In addition to using UPS & Fed-Ex to ship its Industry, & now the only Vehicle to Manual Transmission
packages Whatever It Takes also offers free Night-Box Guide in the industry!
delivery to many areas. By
making this commitment, WIT
Management
helps to increase its customer’s
Kenny Hester, President…….......................800-940-0197 ext.1150
profit margin. With Night-Box
delivery, Builders no longer have Rick Skaggs, VP of Operations....................800-940-0197 ext.1166
to wait around for UPS or FedEx
to arrive; their package is David Bailey, VP of Branch Operations....800-940-0197 ext.1501
delivered overnight so the parts Tom Conroy, VP of Sales & Marketing......800-633-3134 ext. 2134
are waiting on them the next
morning. John Huff, VP of Finance…………….......800-940-0197 ext.1151
Customer Service………………………800-940-0197 ext.1560
© 2010 ATRA. All Rights Reserved.
Ford 71

AWF-21B
Harsh, Erratic or Slow Downshifts/Upshifts
These shift concerns have been caused by several bores wearing out in the valve body.
Always inspect the valve body bores carefully. If worn bores are found the valve body
needs to be replaced or repaired. Always reprogram the TCM with the latest updates.

A bore that is worn has a shine to A bore that is a dull aluminum


it and may have visible ridges. color is in good shape.

© 2010 ATRA. All Rights Reserved.


72 Ford

AX4S/AX4N
Erratic Shifts or Shuttle Shifting
1996-2006 Ford Taurus with an AX4S/AX4N transmission may experience erratic shifts
or shuttle shifting on acceleration from a stop. This condition may be caused by an
erratic VSS/OSS signal coming into the PCM. Check the VSS/OSS signal going to the
PCM. If the VSS/OSS signal is erratic be sure to inspect the wiring from the VSS to the
controller. If the wiring is OK, replacing the VSS sensor may correct this concern.

Early VSS

Late OSS

© 2010 ATRA. All Rights Reserved.


Ford 73

4F50N
Erratic Transmission and Engine Operation
2004-2007 Ford Freestar vehicles may be experiencing erratic transmission operation.
These may include harsh or delayed shifts/engagements, no reverse, erratic engine
operation, engine overheating, engine lean condition, misfire (possibly leading to melted
electrodes on the spark plug) and rough idle.

These symptoms may be caused by water leaking down through the cowl panel (cowl top
vent) and entering the PCM through the PCM connector cover.

Prevent water build


up by removing the
cowl drain plugs
and resealing the
cowl.

© 2010 ATRA. All Rights Reserved.


74 Ford

4F50N/AX4S/AX4N
1-2 or 2-3 Flare Shift
Shift concerns such as a 1-2 or 2-3 flare may be caused by the intermediate piston
cracking. These cracks are very difficult to see. Replacing the intermediate piston with
an updated piston (4F1P-7E005-AA) will usually correct this condition.

The cracks in the piston may be very difficult to


see. Replacing the piston on every rebuild is a
good idea.

Thanks to Tom at Earl Brothers Transmissions, Toledo, OH.


© 2010 ATRA. All Rights Reserved.
Ford 75

6F50N
No Reverse, 3rd or 5th Gears
The Ford Edge, Taurus, Sable, Taurus X and the Lincoln MKX may experience no reverse,
3rd or 5th gears. Trouble codes P0733 (3rd gear ratio error), P0735 (5th gear ratio error),
P0756 (Direct clutch system fault) may be present with the malfunction indicator light
(MIL) on.

To diagnose this condition is simple. Unplug the transmission. Does reverse come back?
If the reverse engagements return then the sun shell is not the issue.

If the forward engagements are good with the transmission plugged in chances are very
high that line pressure is NOT the problem.

Ford has released an updated intermediate sun shell assembly (7T4Z-7A019-A) to


correct this problem.

The weld holding


the sun gear to
the shell breaks.

The updates sun shell


assembly comes with a
new #3 thrust bearing.

Thanks to Nick Medlen from Reliable Transmissions for the broken shell
© 2010 ATRA. All Rights Reserved.
76 Ford

6F50N
PCM Reflashes for Various Concerns
6F50N equipped vehicles may exhibit a harsh driveline clunk at low speed below 10 mph
during stop and go driving. This may be due to a PCM calibration issue. There is a new
calibration to improve low speed stop and go driving feel.

It’s normal for the vehicle to roll while stopped on a slight incline, with the vehicle in drive
or reverse gear and the brakes not applied. There is a new calibration that will improve
the hold capability on a slight grade and improve the ability to creep in drive and reverse.
Customers should be advised that using the brake is still the best way to avoid rolling on
a incline, grade or hill.

Go to www.motorcraftservice.com for the latest calibration files.

© 2010 ATRA. All Rights Reserved.


Ford 77

4R100
No Upshift
While working on a Ford F-series truck with cruise control you may experience a no
upshift condition and possibly code P0500 may be set in the PCM memory. If the cruise
control servo is interfering with the VSS signal, disconnecting the cruise control servo
will usually correct the VSS concern. If disconnecting the cruise control servo corrects
the VSS concern, replacing the cruise control servo assembly is recommended.

Unplug the wires from the back


of the Cruise Control Assembly

© 2010 ATRA. All Rights Reserved.


78 Ford

Torqshift
Dummy Pressure Switches
From the first run of Torqshift transmissions, the solenoid bodies have had pressure
switches built into them. These pressure switches have never been used by the
computer as an input. Early Torqshift valve bodies had five pressure switches and the
late Torqshift only has one pressure switch. These pressure switches can come apart
and leak pressure. Always inspect the pressure switches for breakage. New plugs are
available from the aftermarket.

Aftermarket plug OEM plug


4C3Z-7E440-AA

© 2010 ATRA. All Rights Reserved.


Ford 79

Torqshift
High or Erratic Line Pressure
High or erratic line pressure can be caused by Pressure Regulator Valve bore wear.
If the small end of the valve bore is worn this will allow balance oil to leak off causing
high line pressure.

If the large end bore closest to the spring wears out this will allow converter charge oil
into the boost area of the Pressure Regulator Valve. This may show up on a pressure
gauge as erratic line pressure rise with steady EPC voltage.

Currently the fix is to replace the stator or repair the stator.

Small end bore wear Large end bore wear can lead
causes high line pressure to erratic line pressure with
steady EPC voltage

© 2010 ATRA. All Rights Reserved.


80 Ford

5R55N/W/S
Oil Fill Procedure
The N/W/S transmissions do not have a fluid level indicator stick. When checking fluid
level it must be set at a specific oil temperature. To correctly set the fluid level, use the
following procedures.

1: Use a scan tool to monitor the


Transmission Fluid Temperature (TFT).

2: Start the engine.

3: Note: Engine idle speed is


approximately 650 rpms. Run engine so
that the transmission fluid temperature
is between 27- 47°C (80-120°F).

4: Move selector through all ranges


allowing to engage in all gears.

5: Place the range selector in “DRIVE”.

6: Make sure the vehicle is on a level


platform.

7: Hold the larger fluid drain plug with a


wrench and remove the smaller (center)
fluid level and fill plug with a 3/16-inch
Allen Key.
8: Install the fluid level and fill plug
adapter into the fluid drain plug.

© 2010 ATRA. All Rights Reserved.


Ford 81

5R55N/W/S
Oil Fill Procedure (continued)
9: Prior to filling the fluid transporter/evacuator/
injector with clean transmission fluid, make sure
the canister is clean. Fill with clean automatic
transmission fluid.

10: Hang the fluid transporter/evacuator/injector


under the vehicle. Position it upright and close to
the transmission.

11: Connect the open end of the fluid hose from


the fluid transporter/evacuator/injector to the
fluid level and fill plug adapter in the bottom of
the fluid drain plug.

12: Apply a maximum of 206.85 kPa (30 psi) to


the open end of the vacuum/pressure hose from
the fluid transporter/evacuator/injector. Fluid
will immediately start flowing out of the fluid
transporter/evacuator/injector into the
transmission fluid pan.

© 2010 ATRA. All Rights Reserved.


82 Ford

5R55N/W/S
Oil Fill Procedure (continued)
13: Add one pint of transmission fluid into the
fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the
end of the hose.

14: Inspect the fluid level in the fluid


transporter/evacuator/injector. If the fluid
drains back into the canister, the transmission
is full. If no fluid drains back, more fluid will
need to be added. Repeat steps until full.

15: Pull extra oil out by using a vacuum pump


on the open end of the vacuum/pressure hose.

16: Allow fluid to drain till drips or small stream


is noticed at 27-29°C (80-120°F).

17: Reinstall the small (center) fluid level indi-


cating plug with a 3/16 Allen Key.

18: Check the operation of the transmission by


moving the range selector level slowly through
each gear, stopping in each position and
allowing the transmission to engage.
Always use Manufacture Specific Fluids
High Fluid Level
May cause the fluid to become aerated, due to
the churning action of rotating internal parts.
This will cause erratic control pressure,
foaming, loss of fluid from the vent tube and
possible transmission damage.
Low Fluid Level
Can result in poor transaxle engagement,
slipping, or damage. This could also indicate
a leak in one or more of the transaxle seals or
gaskets.

© 2010 ATRA. All Rights Reserved.


Ford 83

5R55N/W/S
Harsh 2-3 Shifts
Installing a 0.75:1 ratio planet set in place of a 0.71:1 ratio planet set will cause harsh
2-3 shifts. Brain deading the computer will soften the shifts for a few miles but the
harsh shift will eventually return. May also cause a TCC slip code.

NOTE:
Large Sungear = Small pinions on the OD Planet
Small Sungear = Large pinions on the OD Planet

5R55W provides the following gear ratios:


Reverse: 3.07:1
1st : 3.22:1
2nd : 2.41:1
3rd : 1.54:1
4th : 1.00:1
5th : 0.75:1

5R55S provides the following gear ratios:


Reverse: 3.07:1
1st : 3.22:1
2nd : 2.29:1
3rd : 1.54:1
4th : 1.00:1
5th : 0.71:1

5R55N provides the following gear ratios:


Reverse: 3.07:1
1st : 3.22:1
2nd : 2.41:1 (early production) or 2.29:1 (late production)
3rd : 1.54:1
4th : 1.00:1
5th : 0.75:1 (early production) or 0.71:1 (late production)

© 2010 ATRA. All Rights Reserved.


84 Ford

5R55N/W/S
Harsh 2-3 Shifts (continued)
94 Teeth 72 Teeth
0.71:1 Ratio 0.75:1 Ratio

38 Teeth 24 Teeth
0.71:1 Ratio 0.75:1 Ratio

© 2010 ATRA. All Rights Reserved.


Ford 85

4R100, 4R70W with Transfer Case


Erratic Speedometer Reading
1997-1998 Ford F150, F250, Expedition and 1998 Lincoln Navigator, may have erratic
transmission operation or erratic speedometer operation. The malfunction indicator
lamp may be illuminated and code P0503 (VSS) may or may not be stored in the PCM.

A loose speedometer drive gear, located on the transfer case output shaft, may be
causing an erratic VSS signal to the PCM and the instrument cluster. Replace the
speedometer drive gear with a tighter fitting new design speedometer drive gear.

Part # F7TZ-17285- AA

© 2010 ATRA. All Rights Reserved.


86 Ford

4R100, 4R70W
Chatter Type Noise
1997-1998 Ford E150, F150, F250, Expedition or 1998 Lincoln Navigator with a
limited slip differential, may experience a chatter type noise or feeling coming from
the rear axle while turning. This concern may be caused by the differential limited slip
clutch packs being gauged too tightly. Install a Traction-Lock Clutch Pack Kit to correct
this concern.

Parts #'s are F75Z-4947-AA (9.75 ring gear) and F75Z-4947-AB (10.25 ring gear)

© 2010 ATRA. All Rights Reserved.


Ford 87

4R70W/E and 4R75E


Low Speed Tie-up
4R70W/E and 4R75E low speed tie-up (1st gear coast under 10 mph). This may be
caused by a damaged 2-3 (molded rubber design) accumulator piston. To verify the
concern tap into the direct clutch pressure tap. If there is pressure in 1st gear the
accumulator is damaged. Replace the accumulator piston to resolve this issue.

3rd Clutch Pressure Tap

© 2010 ATRA. All Rights Reserved.


88 Ford

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop
In 2001, Ford eliminated the reinforcement plate on the valve body below the third gear
accumulator. The reduced clamping force against the separator plate has caused cross
leaks that stroke the 3-4 shift valve at idle, causing a neutral condition at a stop.

Use the following instructions to modify 2001 and up valve bodies to accept a plate from
an AOD transmission.

Stock valve body without


reinforcement plate

Stock valve body with


modified reinforcement
plate

© 2010 ATRA. All Rights Reserved.


Ford 89

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop (continued)

© 2010 ATRA. All Rights Reserved.


90 Ford

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop (continued)

© 2010 ATRA. All Rights Reserved.


Ford 91

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop (continued)

© 2010 ATRA. All Rights Reserved.


92 Ford

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop (continued)

© 2010 ATRA. All Rights Reserved.


Ford 93

4R70W/4R75E 2001- On
Falling Out of Gear at a Stop (continued)
Use the bolts and reinforcement plate from an AOD.

© 2010 ATRA. All Rights Reserved.


94 Ford

© 2010 ATRA. All Rights Reserved.