HEAD OUT ON THE HIGHWAY
Contents
1. Volume 5 Issue 2 Second Quarter 1998 eo from Mransiec There s Still Time to Enter TransTec s 20th Anniversary Head Out On The Highway Give Away Transmission technicians have until October 1 1998 to enter TransTec s Head Out On The Highway contest to win a new Harley Davidson Super Glide motorcycle The contest cele brates the company s 20th anniversary of supplying transmission professionals with rebuild kits No purchase is necessary but you must be a professional transmission technician or shop owner to participate Official entry forms can be found in In this issue Our Troubleshooter article features Aisin Warner s 6040 the little brother to the AW5040 See page 3 e Win a Harley Davidson Super Glide in TransTec s 20th anniver sary Head Out On The Highway contest See cover article e TransTec now offers the thermo element to case gasket for the CD4E 1993 Up See cover article e Valve body gasket revisions made to the F4A EL in 1996 Up Escort See page 2 e TransTec now offers the new top hat fill tube seal for 1997 up Chrysler RWD models See page 2 e Valve body gasket changes made to 1989 up ZF4HP22 24 See back cover TransTec transmission kits with a date code of A98 to K98 HEAD OUT ON If you open a TransTec kit that doesn t contain an official entry form you can still enter the contest Simply fill out a postcard after reviewing contest rules2. Here s a more than a mouthful picture Beginning from the left side and working right a valve body pressure line b main electrical harness c output speed sensor d e f lube circuit 3 Air checking the 2 4 band servo is simple a servo apply port b servo release port 4 Here are the majority of the electri cal components starting at the top and working our way down throttle pressure control solenoid shift solenoid 1 shift solenoid 2 t c c solenoid transmission temp sensor iv nada Filter Check valve and spring 5 This is under the aluminum alu minium plate that covers the main valve body There are three check balls two filters and one check valve and spring This appears to apply for both Opel and Suzuki applications Suzuki shows no ball here Check valve and spring 6 This is the front valve body main valve body case side Shown is the location of the check ball and the check valve and spring Please note that this is from the Opel unit the Suzuki information shows no check ball being used here So the general disclaimer is that your unit may vary from what you see here Suzuki has a ball here Filter Check valves and springs 7 This is the lower valve body and there is a lot of information to be found here First note the check ball locations Each accumulator cover has a check ball The cover closest to the converter ho
3. models The main valve body gaskets and the upper valve body gaskets as well as their mating separator plates have been changed Only the lower valve body gaskets have remained the same As a result of this revision a new sub kit TransTec No 4861 which contains all the new gaskets for the Prot g will be sub packed within the kits date code C97 or later TransTec 12925 1996 Up Note Gaskets shown are for Ford applications Upper gaskets shown lower gaskets have similar modifications NEWS Denny Scher Editor Rebuilder News is dedicated to providing current technical information to the automatic transmission rebuilder Reader s comments suggestions are welcomed Write Editor Rebuilder News P O Box 556 Milan Ohio 44846 0556 or e mail dps fngp com All rights reserved 1998 Freudenberg NOK General Partnership Reproduction without prior written permission is prohibited Fill Tube Seal Now Available for 1997 Up Chrysler RWD Models TransTec is pleased to announce the availability of a new top hat fill tube seal for the 1997 up Chrysler rear wheel drive models Chrysler has finally followed Ford and GM s lead of nearly 20 years by switching from an O ring to the boot type seal in this application This new seal will be included in all TransTec gasket sets and overhaul kits for the A500 A518 and A618 with date codes of E98 or later Late model A904s and A727s also use this boot
4. presented in TransTec advertisements You can also call TransTec s toll free contest hotline at 1 800 852 0340 ext 6405 for contest information Look for the 20th anniver sary Head Out On The Highway contest entry form the next time you open a TransTec kit become the proud owner of You may a new Harley Davidson Super Glide The drawing for the motorcycle will be held December 1 1998 Thermo Element to Case Gasket for CD4E 1993 Up TransTec is pleased to announce the availability of the gasket for the thermo element to case on the 1993 Up CD4E This gasket is not currently available separately from Ford dealers you are still expected to purchase the complete element This gasket TransTec 12932 will be added to CD4E kits overhaul kit 2295 with date code C98 or later Valve Body Gasket Revisions Made to F4A EL in 1996 Up Escort The F4A EL unit found in 1996 Up Ford Escorts has had some minor valve body gasket revisions The upper valve body separator plate gaskets now have a small orifice in place of the L shaped slot This change affects the upper valve body both upper and lower gaskets These new gaskets will be packaged loose in the main kit TransTec Overhaul Kit No 2265 with date code C97 or later Not to be outdone by Ford Mazda TransTec 12585 1990 95 B jaa o f Z o a fe hn changed almost the entire set of gaskets for 1997 Up Prot g
5. However the seal will only be available in bulk sales for these units Top Hat Seal TransTec 32762 OEM 52118629 Check out our new web site www transtec com Iranslec TROUBLESHOOTER Aisin Warner s 6040 Little brother to the 5040 By Tony Darr Transmission Technician The last issue of Rebuilder News addressed the introduction of Aisin Warner s new AW5040 unit and its slow steady invasion of the domestic marketplace In this issue we address the 5040 s little brother the AW6040 Now you may question why this smaller unit has a larger designation and that indeed is a good question Maybe Bigger Isn t Better The 6040 has four electronically controlled forward speeds a reverse gear and torque converter lock up the same as the 5040 Note that this all happens with one less clutch pack and one less sprag element so maybe bigger is not always better Perhaps 6040 is the project number assigned by the engineers at Aisin Warner when it came time to create Resistance Chart Component Resistance Q Vehicle Speed Sensor Output Speed Sensor Input Speed Sensor Shift Solenoids Pressure Control Solenoid Selector position Gear Position Part Solenoid valve No 1 front drive transmissions for the masses Then again maybe the larger unit came before the smaller one Think about the A904 and the A727 when was the last time you saw a 904 behind a 440 Magn
6. and assistance in providing the transmission core samples and information needed to make this project fly I ll drink a warm beer just for you Lee Also a word of thanks goes to David Bond and Ken Wafstaff of ATP Australia for the information they provided 1 Provided no one else has trampled over this ground before you Aisin was good enough to leave you this map to tell you what you ve got Trouble Codes Diagnostic Area Issued at the start and end of diagnostics When this code is output repeatedly no other DTC is stored in TCM memory Circuit or solenoid shorted to B Shift solenoid No 1 Circuit or solenoid shorted to ground Circuit or solenoid shorted to B Shift solenoid No 2 Circuit or solenoid shorted to ground Circuit or solenoid shorted to B TCC solenoid Circuit or solenoid shorted to ground Vehicle speed sensor output speed sensor Signal voltage low Throttle angle high Throttle opening signal Signal voltage high Throttle angle low Transmission range switch Input speed sensor Circuit or solenoid shorted to ground Throttle pressure control solenoid Solenoid faulty or circuit shorted Engine coolant temperature signal out of range If any other DTCs are in TCM memory this code is output first followed by output of these DTCs starting from the smallest code number in the increasing order and they are repeated 2
7. little barrel seals also inhabit this Aisin unit as well Only three of them are visible in this photo 13 Can you remember doing your first A404 and losing the band anchor pin in the washing machine can This thing will stick tight in the case until you really need it to then you play hell trying to keep it in Ri 14 Unlike the A404 this unit has two more of those pins which are for the parking pawl manual linkage assembly 15 This shows the low and reverse clutch hub which contains the low sprag The sprag elements inner race must lock and free wheel as shown by the arrows when the outer hub is held 16 This must be a Mercedes trick at least there aren t any rivets to chisel out Inside the rear planetary ring gear assembly hidden beneath the plate is a molded rubber seal This seal is for keeping lube oil around the sprag Take a minute to look at this closely the plate can and will go in either way As we all know only one way is right so make sure the pocket for the bearing faces the ring gear and all will go well 17 Here we have the 2 4 band servo Note the adjustment nut on the back side of the apply pin Since this comes in from the bottom side of the case servicing or adjusting the band is reasonably easy 18 Here we go again with those bloody barrel seals This unit has 3 different types and sizes for a total of 10 pieces per unit Not even the 5040 has
8. makes diagnosis relatively easy even if you don t have access to any type of service information The applied elements chart below includes the shift solenoid firing sequence If this unit fails due to any one of its eight electronic signal components going out of whack the O D Off indicator lamp is its way of Over 2nd 4th _ 1st Low Forward drive brake Reverse Sprag Sprag clutch brake Ist 2nd 3rd 4th O D Ist 2nd Ist yelling for help This light will flash a code 12 a single flash one second pause and then a double flash at the beginning and end of trouble code retrieval Hmmmm does this sound like GM to you A chart of trouble codes from the Suzuki service manual is included at right This will at least start you in the right direction The core unit that was used for our initial research is of the Opel variety and is shown in the accompanying photos Differences in the Suzuki version are called out Just as with home loans and cellular phones there s a lot of small print and details Make note of what and where all the little pieces go The following pictures show what we had to work with and are a good representation of what is out there YOUR UNIT MAY VARY ACCORD ING TO MODEL CALIBRATION A Note of Thanks I would like to take a moment to thank Lee Lucas at ATP A T R S England for his support
9. monga CA Creve Coeur MO Kansas City MO Springfield MO Authorized Full Line Distributors Grand Rapids MI Jacksonville FL Memphis TN Nashville TN Norfolk VA Charlotte NC Taylor MI Norfolk VA St Louis MO Pittsburgh PA Mid States Transmission Parts Los Angeles CA Las Vegas NV Oklahoma Transmission Supply Oklahoma City OK Tulsa OK Cleveland OH Forest Park OH Janesville WI A amp Reds Transmission Parts Kansas City MO Simi Valley CA San Diego CA Kent WA Lindenhurst NY Bensenville IL Birmingham AL Cincinnati OH Sacramento CA Sacramento CA Orange CA San Jose CA Texarkana TX Little Rock AR Shreveport LA Valve Body Gasket Changes Made to ZF4HP22 24 1989 Up There has been an update in the 1989 up ZF4HP22 and ZF4HP24 valve body gasket This change involves the addition of two new holes and the revision of two existing holes The new gasket TransTec 12954 OEM 1043 328080 will retrofit all previous 1989 up models and will be added to TransTec over haul kit 2192 when stock of the previous part is depleted New Gasket TransTec 12954 TransTechnical Bulletin Previous Gasket TransTec 12457 ransilec Bak Rat P O Box 556 U S Postage Paid Milan Ohio 44846 0556 USA Sandusky OH 44870 Permit 70 Foma Aftermarket Division
10. that many Oh by the way there are no case or cover gaskets for this unit Use a brand of RTV that you trust or use Suzuki Bond No 1216 part 99000 31160 and be careful how much you apply Scarf cut i EFAN 19 lwant to draw your attention to the fact that the sealing rings on the forward clutch drum are not created equal The upper and lower rings are butt cut teflon seals while the center seal is of the scarf cut variety All three are the same size and material so please don t get them mixed up 20 Here is the O D and coast clutch housing In the center of it is the rear planetary ring gear assembly Why are we looking at this you may ask Because the forward sprag is also hiding in here As shown the element must free wheel and lock in the directions indicated by the arrows while the drum is held Mississauga ON Los Angeles CA San Leandro CA Sacramento CA San Diego CA Regina SK Vancouver BC APD Transmission Parts ATG Auto Trans Group Inc Edmonton AB Vancouver BC Philadelphia PA Orlando FL D amp E Automotive Sales Hazel Park MI Lincoln Park MI San Antonio TX Van Nuys CA Grand Rapids MI Dean Transmission Springfield MA Pennsauken NJ Colorado Springs CO Denver CO Las Vegas NV Albuquerque NM Portland OR Federal Transmission Sun Valley CA Salt Lake City UT Seattle WA Spokane WA Rancho Cuca
11. um engine They re Already Here The 6040 made its debut in the 1995 Suzuki Esteem introduced in the states by Suzuki Motors to compete with compact cars like the Toyota Corolla Nissan Sentra and Mazda Protege Yes that means there are a few of these cars running around as you re reading this It must be a pretty good seller since Suzuki s introducing a station wagon model in 1998 as well Anyway this transmission has been tooling around England in various Opel models since at least 1992 It can also be found down under in select Holdens Daihatsus and Suzukis More Info s Available Unlike the 5040 the 6040 is not APPLIED ELEMENTS On Solenoid TCC Forward Reverse Coast valve control clutch clutch clutch No 2 solenoid Off J On only when TCC is operating likely to be found behind high torque V 6 s and inline fives although it has been coupled to a turbo charged four banger in the UK Consider yourself lucky when it comes time to repair one of these units There is much more information available for the 6040 than the 5040 The Suzuki service manual is a very good source to start with unless you have an Opel version The Opel version has only a few variations most of which are in the valve body This AW6040 s clutch and band application strategy is very close to that of the 4L60 with the exception of the coast clutch being applied in all ranges except fourth gear This
12. using also has a spring which acts upon the accumulator piston directly below it The valve body itself has 5 check balls Suzuki has 6 as shown with the box one filter and three check valves and springs Make a note of the one check ball that is a larger diameter than the rest and is marked with a triangle Unlike the 5040 this unit uses O rings for the accumulator seals All four are the same size however the pistons are not The accumulator piston shown on the top left side has a shallower pocket than the rest This was done to accommo date the spring residing in the cover Once again this is for general knowl edge Your unit may vary so be cau tious when opening this thing up 7 i 8 Remembering lessons learned from the big brother the AW5040 these two seals lie waiting under the valve body The upper seal is for sealing low and reverse fluid pres sure while the lower is for sealing lube oil to the low sprag 9 Ok class can anyone tell me where the pump is 10 That s right Jimmy you must first remove the bellhousing half of the case to access the front pump 11 Here is the pump showing the O ring used to seal the pump to the case Also shown is the reverse clutch housing found directly behind the pump Note there is no gasket between the pump and case Make sure surfaces are clean and flat when you torque the pump in place 18 ft Ibs 12 Here we see that those pesky
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