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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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 07458
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.
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PUMP SERVICE
FIGURE 18-10 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.
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PUMP SERVICE
FIGURE 18-11 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 07458
PUMP SERVICE
FIGURE 18-12 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.
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PUMP SERVICE
FIGURE 18-13 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 07458
PUMP SERVICE
FIGURE 18-14 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 07458
PUMP SERVICE
FIGURE 18-15 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 07458
PUMP SERVICE
FIGURE 18-16 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 07458
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.
Automatic Transmissions and Transaxles, Fourth Edition
By Tom Birch and Chuck Rockwood
FIGURE 18-17 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)
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
PUMP SERVICE
FIGURE 18-18 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 07458
PUMP SERVICE
FIGURE 18-19 Special tool J25025-1 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 07458
TECH TIP
• An alternate aligning
method is to place the
pump upside down in an
empty transmission case
before tightening the bolts.
FIGURE 18-20 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 07458
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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-21 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-22 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.
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CLUTCH ASSEMBLY SERVICE
FIGURE 18-23 This variety of clutch spring
compressors includes completely portable ones (a, b,
and c), a bench-mounted style (d), and a large, footoperated 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-23 (CONTINUED) This variety of clutch spring compressors includes
completely portable ones (a, b, and c), a bench-mounted style (d), and a large, footoperated 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 07458
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 18-24 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-25 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.
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TECH TIP
FIGURE 18-26 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-27 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-28 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-29 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 07458
TECH TIP
• Always check to be sure the plates turn freely with the clutch
released.
FIGURE 18-30 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 07458
CLUTCH ASSEMBLY SERVICE
FIGURE 18-31 The clutch pack clearance
specification for this clutch is 0.025 to 0.045
in.(0.64 to 1.14 mm). A 0.025-in.feeler gauge
should enter as shown, but a 0.045-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.
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TECH TIP
• Clearance can also be
measured using a dial
indicator.
FIGURE 18-32 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.
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TECH TIP
FIGURE 18-33 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.
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TECH TIP
FIGURE 18-34 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 07458
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 18-35 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 07458
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 18-36 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 07458
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 07458
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 18-37 This gearset should have 0.005
to 0.048 in. (0.12 to 1.22 mm) of end play. A
0.005-in. feeler gauge should enter as shown,
but a 0.049-in.gauge should not. (Courtesy of
Chrysler Corporation)
Automatic Transmissions and Transaxles, Fourth Edition
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GEARSET SERVICE
FIGURE 18-38 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.
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GEARSET SERVICE
FIGURE 18-39 Planetary gear train damage shows
up as wear (a–d) or cracks and breakage (e).
Automatic Transmissions and Transaxles, Fourth Edition
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GEARSET SERVICE
FIGURE 18-39 (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.
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GEARSET SERVICE
FIGURE 18-40 These three gear train components
show severe wear and scoring in the thrust surfaces.
Automatic Transmissions and Transaxles, Fourth Edition
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GEARSET SERVICE
FIGURE 18-41 These sun gear drive shells show stripped splines (a) and broken, dislodged splines (b).
Automatic Transmissions and Transaxles, Fourth Edition
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© 2010 Pearson Higher Education, Inc.
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GEARSET SERVICE
FIGURE 18-42 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.
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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
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VALVE BODY SERVICE
FIGURE 18-43 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
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VALVE BODY SERVICE
FIGURE 18-43 (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
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TECH TIP
• Some technicians make a
valve organizer by folding a
piece of cardboard into an
accordion shape.
FIGURE 18-44 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.
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TECH TIP
FIGURE 18-45 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
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VALVE BODY SERVICE
FIGURE 18-46 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.
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VALVE BODY SERVICE
FIGURE 18-47 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
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TECH TIP
FIGURE 18-48 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
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TECH TIP
FIGURE 18-49 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
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TECH TIP
FIGURE 18-50 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 offcenter. 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
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VALVE BODY SERVICE
FIGURE 18-51 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
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TECH TIP
FIGURE 18-52 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
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TECH TIP
FIGURE 18-53 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
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TECH TIP
FIGURE 18-54 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
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TECH TIP
FIGURE 18-55 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
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VALVE BODY SERVICE
FIGURE 18-56 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 07458
VALVE BODY SERVICE
FIGURE 18-57 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 07458
VALVE BODY SERVICE
FIGURE 18-58 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 07458
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 18-59 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 07458
VALVE BODY SERVICE
FIGURE 18-60 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 07458
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 07458
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 18-61 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 07458
DIFFERENTIAL SERVICE
FIGURE 18-62 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 07458
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 07458
REVIEW QUESTIONS
1.
The areas of the case that should be inspected are:
a.
b.
c.
d.
e.
f.
2.
3.
4.
5.
______
______
______
______
______
______
The pump should be inspected for _________ marks and damage to
the gears and housing.
When assembling a pump, it might be necessary to _________ the
pump halves before torquing the pump body bolts.
Like a gear pump, a vane-type pump should be _________ inspected.
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 07458
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
CHAPTER QUIZ
7. Clearance in a multiple-disc clutch is adjusted
using any of these selective parts, except
a)
b)
c)
d)
clutch pressure plates.
clutch housings.
pressure plate snap rings.
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 07458
CHAPTER QUIZ
7. Clearance in a multiple-disc clutch is adjusted
using any of these selective parts, except
a)
b)
c)
d)
clutch pressure plates.
clutch housings.
pressure plate snap rings.
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458
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)
b)
c)
d)
Student A
Student B
Both A and B
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 07458