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RE0F05A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Jatco CVT RE0F05A (also known as NCVT) is commonly installed on small cars with engines having the capacity up to 1500 cm3. In terms of control, this transmission is fully hydraulic, i.e it includes the block of hydraulic valves like in standard automatic transmissions, but the transmission operation is performed thanks to movement of the main pulley.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	135	3,2	3	D Fluid N-CVT

The main problem of this transmission lies in increase or decrease of the gear ratio, like an emergency mode (2-nd gear). The repair of this transmission should be performed by professionals on a special bench.

BTR M78LE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

6-speed automatic transmission DSI-6 \ M78LE (M96) was developed in 2008 by specialists of former BTR bureau with a new Chinese owner Geely under a new brand DSI. It is more advanced modification of 6-speed automatic transmission with a longitudinal positioning for 2-liter engines SsangYong Actyon.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD/AWD		9,5	4,5	ATF 3292

Technical issues and repair guidelines

In many cases vibrations from the worn-out torque converter lead to the damage of the oil pump bearing. The pump with the planetary gear is considered to be a soft spot of 6-speed М78. The planetary gear is damaged by increased torque and vibrations from the torque converter. With regard to electrics solenoids-electric controllers, shifters and solenoids-electric controllers M78 are replaced in this transmission.

How to repair this transmission (Videos)

TCC Shudder Repair

Solenoid valve test M78

BTR M74LE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission BTR M74LE with a longitudinal positioning for RWD vehicles was designed in 1988 by BTR company on commission from a Korean automaker SsangYong for its flagship SUV Korando. In 1989, this RWD transmission was launched in mass-production. In most cases, the M74LE transmission was mated with 2-3-liter engines and found application in RWD SsangYong models - Rexton, Actyon, Korando etc. The 6-speed automatic transmission DSI-6 \ M78LE (M96) was developed in 2008 by specialists of former BTR bureau with a new Chinese owner Geely under a new brand DSI. It is more advanced modification of the 6-speed automatic transmission with a longitudinal positioning paired with the 2-liter engines SsangYong Actyon.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		9	3,5	BTR M74LE

Technical issues and repair guidelines

In most cases, М74 and М78 transmission models require ATF change and filter replacement during the overhaul. In addition, specialists usually order the pan gasket. For reassembly of М78 (and М74) specialists order the repair kit of gaskets and seals /Overhaul kit and a complete kit of friction components. Brake bands (Intermediate (Direct, High/ Reverse) ) are also considered to be spare parts for this transmission. The rear brake band is replaced in case of burnt fluid and uneven wear-out and the band clearance, in order to exclude kicks in the process of gears shifting.

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

BTR М11 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission BTR М11 with east-west positioning was installed on New Actyon (Corando С) in 2010. This transmission was paired with the 2-liter diesel engine having the torque up to 380 Nm. In 2012, after implementation of some changes the М11 unit was modified with introduction of different improvements. This transmission is intended for FWD as well as AWD SUVs.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/AWD	380	7,5	4	SsangYong 0578-244021

Technical issues and repair guidelines

Typical repair procedures for this transmission include reassembly and replacement of rings, seals, and gaskets (Overhaul kit). In many cases, the whole set of friction components is replaced by repair specialists. The wear-out of frictions leads to clearance increase in clutch packages. Abnormal (increased) clearances in clutch packages (and braking drums) lead to jolts and increase the risk of vibrations under load. Replacement of the brake band with a servo piston is performed in case of vibrations detection in the B1 (555) Drum or shifting with the kick or there is uneven wear-out of servo piston and brake clearance.

The necessity to replace of the rear planetary gear in the М11 transmission lies in overloading caused by aggressive driving and neglect of the automatic transmission maintenance services. The oil pump is one of the most popular issues in the M11 unit. This pump breaks down in situations when the overhaul of the transmission and its torque converter is delayed for a long time, consequently leading to extreme vibrations in the torque converter, complicated by contaminated fluid. The piston of the В2 brake package is frequently replaced in this transmission. This piston gets out of order because of overheating and a long-term operation with vibrations. Solenoids are included in the list of commonly replaced spare parts. The M11 transmission design includes 6 VBS solenoids with different holders.

How to repair this transmission (Videos)

New Actyon BTR M11

6F24 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6F24 transmission model replaced not very successful M11 model in 2013. This transmission has been installed on Dodge Dart, Jeep Compass, Patriot MK since 2013. In terms of design, this transmission is a copy of the A6MF transmission. For integration of this transmission with SsangYong engines, engineers had to modify electrical part of this transmission, including solenoids and the software.

Technical issues and repair guidelines

This transmission has the same typical problems as A6MF1 and A6MF2 transmissions.

The ATF change should be performed after 80 travelling thousand kilometers, but the fluid condition should be controlled every 20 thousand kilometers. In case of aggressive driving manner it may be necessary to change the fluid earlier. The filter for the 6F24 unit is replaced only with removal of the cover and repair/cleaning of the valve body. Specialists recommend to clean the valve body and replace the filter after 120-140 thousand kilometers (when detecting first signs of improper gears shifting) without waiting for wear-out of solenoids. Transmission specialists repair the torque converter if the fluid becomes very hot and gets rapidly contaminated.

Engineers of SsangYong adjusted the valve body operation for 6F24 not very carefully, therefore the torque converter slipping (as in Hyundai) and aggressive driving behavior may lead to the lock-up clutch damage by the torque converter by the end of the car warranty period.

How to repair this transmission (Videos)

A6MF1 4WD Teardown

A6MF1 TRANSMISSION TEAR DOWN

724.0 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Mercedes in cooperation with Getrag had developed 7-speed DSG (7G-DCT) with a dual clutch by 2012. This transmission is intended for vehicles of А, B, CLA, GLA classes.

Mercedes has taken into account the experience of VAG in this field and equipped its DCT with a wet clutch, which can operate withmore powerful engines. This transmission is equipped with an electric oil pump, which is engaged when a quick start is required or in case of the maximum load.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DCT	FWD	350	7,2	6	236.21

Technical issues and repair guidelines

The fluid quality monitoring is the only measure required during the first years of operation of this transmission. After 60-80 thousand kilometers, it is recommended to check the fluid state and change with the filter, if some contamination or smell is detected. Mercedes engineers delicately adjusted the mechanism of gears shifting in this transmission and ATF contamination can significantly change the performance capacity of the dual-clutch mechanism.

Therefore 7-DCT has two fine mesh filters:

1. One filter is positioned In the pan – metal-plastic filter with a felt membrane. It is recommended to replace it and change fluid after 100 thousand kilometers.

2. The second filter is placed outside – the filter-cartridge. It should be replaced yearly or after travelling 30-40 thousand kilometers.

How to repair this transmission (Videos)

7G-DCT

Mercedes-Benz 7G-DCT

7G-TRONIC PLUS

7G-TRONIC Plus Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	autocats.ws	System description 724.0
web	bevo.mercedes-benz.com	7-G DCT transmission oil
pdf	alltranz.co.nz	Scheme 724.0

A727 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The A-727 is a 3- speed automatic transmission designed and manufactured by Chrysler in the early 1960-s (replaced A488). Since then, this gearbox mainly had been mounted on a different Chrysler cars. This gearbox is extremely adjustable and powerful enough to operate with 450hp engines. Therefore, A-727 may be easily used for Chrysler, GM or AMC vehicles.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		8,2	3,8	Mopar ATF+3

Technical issues and repair guidelines

This type of transmission may be specified by peculiarly shaped 14-bolt oil pan. The A-727 uses a paper fluid filter and has 2 transmission bands (reverse and kick-down). It had been one of the most adaptable Chrysler gearboxes for over 3 decades, due to its durability and efficiency. Therefore many automakers selected A-727 for their products.

After some time this transmission received new names and broken up into 2 categories of the 36RH and 37RH gearboxes, where "3" specifies that it is a 3-speed gearbox, "6/7" are strength indications, "R" means that it is designed for RWD application.

How to repair this transmission (Videos)

A727 Transmission Rebuild - Part-1

727 from a first gen Cummins rebuild part 1

727 from a first gen Cummins rebuild part 2

Instruction manuals and useful links

Link type	Source	Description
pdf	shop.ukrtrans.biz	Repair manual A727
web	hotrod.com	15 Tips to Improve Your 727 Torqueflite Trans
web	novak-adapt.com	Guide to the Chrysler 727
web	Wikipedia	TorqueFlite A727 (36RH/37RH)

MENA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

MENA is a continuously variable transmission of the first generation produced by Honda (all range including MENA, SETA, SENA, META has a common name Multimatic). These transmissions had been installed in Honda HR-V of the first generation from 1998 until 2005. In fact, it is one CVT which has 4 modifications.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		5,9	3,2	Honda Genuine CVT

In fact, these CVTs (together with M4VA (S4VA, S4PA, S4MA)) are considered to be one of the oldest CVTs produced by Honda.

As a matter of fact, it is one CVT in several modifications. Modifications of CVT are bound to letter designation of the car body:

· GH1 – MENA

· GH2 — SETA

· GH3 – SENA

· GH4 – META

Typical issues

Honda CVTs related to the Multimatic series (META/SETA/SENA/MENA) usually have the same issues as CVTs of the M4VA (S4VA,S4PA,S4MA) series. Actually, META series was designed on the basis of the M4VA

-Problems with starting from the rest (jerks, speed drift when applying D+brake). This problem is fixed by replacement of the start package valve. In neglected cases specialists replace the start package.

-Problems with speed drifts in the process of acceleration have 2 solutions: 1) Replacement of the gear ratio valve 2) replacement of seals on the input shaft. This procedure requires partial disassembly of the gearbox. It is desirable to use the original repair kit of gaskets.

-Problem with the reverse. This problem is caused by damage of reverse brake elements. This problem is solved by CVT disassembly and welding. In addition, it is required to replace piston rubbers of the reverse brake – these rubbers may tear leading to problems with the reverse.

To prevent any further problems with the reverse, it is recommended to replace reverse friction clutches.

AP2 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

AP is the 4-speed automatic gearbox created by Automotive Products and the BMC for MINI vehicles. The prototype of this famous gearbox was released in 1962. It took about a decade of engineering and manufacturing efforts before ordinary 2-speed gearbox turned into the unique 4-speed automatic gearbox.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD

Technical issues and repair guidelines

This was a great achievement to manufacture a 4-speed automatic gearbox that could be operated like a manual unit. It was one of the first automatic gearboxes with east-west mounting produced for FWD vehicles. Moreover, the construction of this gearbox implies the usage of lubricating oil instead of common ATF. This gearbox was also installed in BMC ADO16 and Austin vehicles. Specialists claim, that the crankcase oil should be changed every 10 thousand kilometers, because the oil condition is very important for this type of gearbox. One of the most common malfunctions in this transmission is related to the F-clutch that may get out of order because of the gearbox construction peculiarities (clutch gets the drive torque after multiplication via the gearbox).

How to repair this transmission (Videos)

Classic Mini Remote Gearbox Rebuild

Old Classic Mini Gearbox Rebuild - Part 1

Old Classic Mini Gearbox Rebuild - Part 2

Old Classic Mini Gearbox Rebuild - Part 3

Old Classic Mini Gearbox Rebuild - Part 4

Classic Mini Differential Rebuild - Part 1

Classic Mini Differential Rebuild - Part 2

Classic Mini Idler Gear - Setting The End Float

Fitting the crankshaft and checking the endfloat

Fitting the pistons, camshaft & oil pump

Setting the cam timing

722.2 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The first two modifications 722.1 and 722.2 of the family of automatic transmissions are rarely found in repair services. Commonly, this automatic transmission is installed on cars produced in the 80th. Owners of cars with the 722.2 transmission prefer the transmission rebuilding in order to preserve a rare car.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		7	4	236.12

Technical issues and repair guidelines

Visually the automatic transmission 722.2 is distinguished by small square pan with reinforcement ribs. The automatic mechanism controlling the process of gear shifting is located in the pan of the housing and appears to be a separate unit in contrast with automatic transmission designs of the following series. Shafts and planetary gears in this automatic transmission are highly precise and of high quality almost without application of aluminum alloy and plastic, seals are made of metal rings. The resource of these parts is much higher than the resource of friction components and in some cases of the car itself. If the transmission starts to transmit the rotation of shafts improperly, shifts gears with jolts, then it is required to perform the emergency repair (in this case replacement of some friction elements). Further usage of a faulty transmission may lead to its replacement. Signs of pumps damage consist in leaks between the transmission and the torque converter. In case of the pump wedging, it is required to replace the torque converter.

How to repair this transmission (Videos)

Mercedes 190E Teardown

Instruction manuals and useful links

Link type	Source	Description
web	Wikipedia	Mercedes-Benz first series automatic transmission
pdf	transmax.co.nz	Scheme 722.2
web	cardiagn.com	Download link on Manual 722.2
web	cardiagn.com	722.1-722.2 Transaxle Service Manual See link

BW65/66 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

BW65/BW66 automatic transmission is mounted on the BMW Bavaria (1971 – 1974) and Jaguar XJ6 (1980-1987). This complex system combines electronic, mechanical and hydraulic components. But despite of high degree of safety some problems may occur in the process of transmission operation.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		10	4-4,5	ATF Type F

Technical issues and repair guidelines

When the slippage takes place during the operation of this type of transmission it may lead to slow gear-shifting and vibrations, therefore it is an important signal for visiting repair services.

The most common problems related to this transmission are:

- shortage or surplus of oil;

- long slippage;

- sharp driving dynamics.

The sleeve and other parts of BW65/66 transmission can get overheated that usually leads to overheat cracks and other mechanical damages.

BW35 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The BW-35 is an A/T manufactured by the BorgWarner in the 1950s particularly for engines with the capacity of less than 200 cu.in. The modification 35 is a 3-speed A/T coupled to the engine by a three-element torque converter.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		8,2	4,5	Type F Fluid, Dexron II

Technical issues and repair guidelines

Engine power is converted into hydrokinetic energy and this provides smooth application or driving torque. This transmission has 3-forward and 1- reverse transmission ratio. It was constructed for operation with Type-F oil, which is not so popular today as Dexron.

The hydraulically operated control unit includes a valve location and a pump activated by the engine. The automatic gearbox includes a planetary set having 2 center gears, 3 sets of 3-epicyclic gears which can be found in a planet gear holder and follower gear.

Instruction manuals and useful links

Link type	Source	Description
pdf	volvoenthusiastsclub	Repair manual BW35

FW6AEL Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed FWD automatic transmission FW6A-EL with the east-west mounting was developed by Aisin for Mazda. This transmission was installed on Mazda CX-5 with the 2.0 liter engine, Mazda-3, Mazda-6. In terms of design, this transmission is very similar to the U660E transmission produced by AisinWarner. This transmission is considered to be the main competitor of ZF 6HP19-21. The FW6A-EL transmission has the torque converter with a double lock-up clutch that helps to accelerate the transmission faster and with higher efficiency. However, frequent usage of kick-down may lead to failures. This transmission employs reliable Aisin solenoids – linear type solenoids with anodized manifold, which is built into the solenoid body.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD	300	8	5	ATF-FZ Skyactiv

This transmission is a “rare guest” in the repair services, repair specialists mainly change oil and filter. It is recommended to change ATF after reaching the mileage of 100 thousand kilometers, and then every 50-60 thousand miles. It is required to monitor ATF transparency regularly, because with aggressive driving style ATF may get contaminated much earlier. In rare cases, transmission specialists face the problem when the torque converter lock-up damages the pump. The issue is expressed in vibrations and leakages through the pump seal. In this case specialists not only replace the seal, but also repair the torque converter and replace clutches. Another problem, similar to the issue in U660E, is wear of the case center bearing. This problem occurs when drivers get carried away with the kick-down on cold oil. One more typical problem of this transmission is damage of the double drum High/Low. After running 100 thousand kilometers it is also recommended to monitor the ATF temperature and the heat exchanger operation, similar to VW problems with the TF60-SN transmission. In old cars repair specialists advice to clean the heat-exchanger during full ATF change, to ensure reaching of 300 thousand kilometers mileage before the overhaul.

Instruction manuals and useful links

Link type	Source	Description
pdf	alltranz.co	Scheme FW6AEL
web	nema.club	DTC P0731 1GR incorrect ratio
web	nema.club	DTC P0746 Pressure control solenoid stuck off

C635 DCT Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed C635 dual dry clutch transmission (DDCT) was produced by Fiat and was presented in 2010 with AWD, FWD, and manual versions. Since then, this transmission has been installed on Alfa Romeo 159, Brera, Gulia, Milano, MiTo, Spider. This transmission was designed thanks to collaboration of Fiat, Magnetti Marelli and BW. The maximum torque transmission capacity of the C635DDCT is equal to 350 Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DCT	FWD	350	2,1	1,9	Addinol ATF DCT

The total weight of this transmission is 81 kilograms, including ATF and TCU. The advanced technologies implemented in this transmission guarantee uninterrupted torque transmission and traction without any losses of power in the process of gear shifting. The Start/Stop feature helps to reduce fuel consumption by 10% in comparison with standard hydro-mechanical transmissions.

Transmission repair specialists point out that the C635DDCT transmission is extremely sensitive to the ATF condition. Constant monitoring of the ATF status may prolong the service life of this transmission.

How to repair this transmission (Videos)

Fiat Dual Dry Clutch Transmission

Instruction manuals and useful links

Link type	Source	Description
web	Wikipedia	FPT C635 DDCT transmission

TF690 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The CVT transmission version named TF690 (Lineartronic) was designed in 2008 for Subaru Outback with the engine capacity equal to 2.5 liters. The second generation was named as TR580. In 2010, this CVT was tested on Impreza with the engine capacity from 1.6 to 2.0 liters. Starting from 2012, this transmission also found application on other Subaru models. The design of middle class CVTs includes a chain instead of a push belt. This CVT is quite sensitive to the fluid state, its cleanness and temperature. There is a special type of oil for this CVT named as SUBARU CVT Oil Lineartronic II (K0425Y0710).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	AWD	350	12,5	5,6	SUBARU CVT Oil Lineartronic II

Technical issues and repair guidelines

The repair kit of gaskets and seals is used to replace rings and gaskets. Rubber rings are replaced when the CVT unit is overheated or if it operates with contaminated fluid (including chips) for a long time. In case when frictions burn to the glue layer, the filter with the mesh is also replaced in the process of the TF690 reassembly. Burnt frictions and Forward steel discs are the first to be replaced. Next on the popularity of the replacement are the metal frictions of the Starter package. The starter pack is responsible for turning the cones on and off when stopping and shifting the lever to the neutral position. Transfer frictions also appear in replacement operations. They are responsible for distribution of torque on rear\front wheel drive.

The TR580 unit has problems with the valve body and a set of solenoids. In previous models these components caused the failure of electrics when the transmission operated with contaminated oil for a long time or under extreme loads and temperatures. When the wear-out of the belt and cones is neglected, then it is necessary to replace the cones. A typical problem with CVT cones in Subaru is related to the input shaft bearing, pressed in the transmission body. This bearing is cranked by vibrations at maximum speeds, and then it breaks.

How to repair this transmission (Videos)

Valvebody Replacement with code P2764

Breaking down a TR-580

GS7D36SG Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission GS7D36SG was designed by 2008 for BMW vehicles with engines having the torque up to 400 Nm. This transmission has 7 speeds and minimum possible 100 ms of the torque disruption. This transmission also named as M-DCT and DSG-7 BMW. Initially this transmission was installed on rare BMW M3, Z4. After testing, computer adjustment, improvement of the cooling system this transmission was offered for cars of E90/92/93 series, and later for E82/88 series. In addition to impressive characteristics of the acceleration dynamics this transmission has a solid reserve in durability (for 100 thousand kilometers).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DCT	RWD	400	9,5	5	83222148578

Technical issues and repair guidelines

Manuals say that it is not necessary to change ATF for this transmission during the whole service life of this unit, but repair specialists recommend to perform this procedure to prolong the lifespan of this transmission. This transmission has all modern security systems from overheating. Friction components are selected with steel discs for each type of engines, require correct positioning during installation (for efficient cooling),violation and get burnt in case of violation of operation rules. The friction lining wear-out increases clearances in the package and the transmission starts shifting gears improperly. Before replacement of friction components it is recommended to consult an authorized DSG BMW service, because it may be possible to adjust shifting with worn-out frictions with the use of software.

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme GS7D36SG, DCI600

CTX Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In 1987 Ford and Fiat started to produce the type of automatic transmission called CVT. This innovative system was designed on the basis of the Van Doome mechanism, which was installed in small cars (DAF) in 1955.

The Ford CTX transmission operates on the principle of belt driving applied in Van Doome transmissions, but with some peculiarity, namely, usage of a single steel belt (operating in compression) instead of two rubber drive belts (operating in tension).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		3,6		MVATF PLUS

Technical issues and repair guidelines

This type of gearboxes is used for FWD vehicles with the capacity up to 1.6 liters. It is claimed, that this transmission is more economically viable solution in comparison with usual automatic gearboxes.

This transmission has a smoothly shifting gear ratio over the entire speed range. Transmission of the torque from the engine to the main drive shaft is performed not via converter, but through the multi-plate clutch. The transmission control unit provides an optimal gear ratio for any driving mode with a maximum efficiency coefficient of the engine. There is a kick-down mode which facilitates to the speed increase in cases of overtaking or uphill movement. This mode is activated when the accelerator pedal is fully depressed and held in this state.

Instruction manuals and useful links

Link type	Source	Description
pdf	alltranz.co	Scheme ford ctx
web	pirmil.info	Scheme image CTX

722.7 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 722.7 (W5A180) had been used since 1998 until 2005 on vehicles of А-class (A168, А190) with the engine capacity up to 2.0 liters as well as on VANEO (W414) with the same type of engines.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD	205	6,3	3,3	236.12

Technical issues and repair guidelines

Before covering 200 thousand kilometers these automatic gearboxes get in repair services for 2 reason

1. The clutch drum К1

Due to construction peculiarities of the 722.7 unit and its valve body (VB), at one of the phases of clogging and aging of the 722.7 electrics transmitted excessive pressure on this pack damages the metal of the drum with the piston or pulls out the closing ring, that leads to slipping and necessity for change of the entire clutch cover K1. Preventive measures include well-timed cleaning of the VB unit, or well-timed change of the TC lock-up clutch after gearbox travels 150-200 thousand kilometers.

2.Valve body electronic plate

For proper diagnostics and repair estimation, it is necessary to obtain error codes. Change of the board sensors or wiring of solenoids demands classification of the specialist and programming capabilities for encoding the plate for VIN of the car. Mercedes electronic boards are sensitive to the water, temperature difference, metal chips in oil. Each time diagnostics detects various causes of abnormal operation. The minor repair helps to delay the preventive repair for several years by means of cleaning\washing of the VB unit, repair of the electric plate with broken sensors. Operation with overheated oil damages the electronic plate extremely fast.

How to repair this transmission (Videos)

inspect Mercedes A class automatic gearbox

slipping in first gear

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Electronic and Solenoids scheme

K210 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TOYOTA K210 / XA-15LN

Simultaneously with the first generation of CVTs (K110/K111/K112), the Japanese company Aisin designed a lightweight CVT version K210 intended for small cars (with engine capacity of 1.0-1.5 liters). The right-hand drive Toyota Vitz (engine capacity 1.3 liters) was the first car equipped with this CVT. This car was intended for sale on the domestic market of Japan. Toyota wanted to test this CVT in Japan and fix all possible issues. The first upgrade of K210 was implemented in 3 month after its launch – Aisin engineers changed the belt. This measure helped to improve the car performance reliability at idle speed. In 2004, CVTEC Co., Ltd started production of 30-millimeter CVT belts, which found application in K210 (before that, the K210 gearbox was equipped with the belt of the Dutch company VDT BV).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	145	8	5	Aisin CVTF7004, Toyota 08886-02105

For the external market (car models not including Toyota), Aisin produced the modification of K210 named as XA-15LN. From 2007 to 2014, this CVT had been successfully used by the company Mazda in its cars (Mazda Demio and Mazda Axela). It should be noted that modifications of the K210 transmission are not interchangeable (or partly interchangeable).

The range of K210/XA-15LN did not receive any continuation. CVTs of this series were installed on a limited number of models of Toyota and Mazda for the domestic market of Japan. These CVTs had been produced before the end of 2015.

In 2004, Aisin developed a new range of CVTs (K410/K411) for Toyota cars with 1.3-1.5 liter engines. This series turned out to be quite successful.

Typical problems:

1) CVTs of K210/XA-15LN series (as well as other CVTs produced by Aisin) are extremely sensitive to ATF quality. In this case, we are talking not only about the presence of metal shavings in ATF, but also about ATF overheating. Shavings in ATF are actually abrasive particles, which eventually (if ATF is not changed) damage Teflon rings in CVT. Then it leads to ATF pressure drops in the transmission itself. Severe wear of Teflon rings over time leads to damage of friction clutches and steel discs.

2) Overheating of the CVT K210/XA-15LN often leads to complete replacement of friction discs. If the driver continues using the transmission with burnt ATF for a long time, then ATF not only loses it qualities and cools the transmission insufficiently (often it leads to overheating and replacement of pistons), but also poorly lubricates cones (especially in winter mode). It leads to slipping of the belt in winter time. Early versions of K210-11A CVT modifications were equipped with belts of the company VDT BV. These belts are not interchangeable with later modifications of belts produced by “CVTEC Co., Ltd.”.

3) Shavings (if ATF is not changed) reach bearings on the input and/or output shaft of cones and eventually one of bearings starts “buzzing”. Bearings are not very expensive, but replacement of

the “buzzing” bearing is possible only with removal and complete disassembly of CVT (this procedure is time-consuming).

4) Some drivers had to deal with the problem of seal leakages in K210. Replacement of seals is usually combined with ATF change

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Daihatsu	BOON	10-16	CVT FWD	L4 1.3L
Daihatsu	BOON/BOON LUMINAS	10-11	CVT F/4WD	L4 1.3L
Subaru	TREZIA	10-16	CVT FWD	L4 1.3L
Suzuki	SPLASH	08-11	CVT FWD	L4 1.2L
Suzuki	SWIFT	07-11	CVT FWD	L4 1.2L
Toyota	PASSO	10-16	CVT FWD	L4 1.3L
Toyota	RACTIS	06-11	CVT FWD	L4 1.3L
Toyota	VITZ	05-16	CVT FWD	L3 1.0L

VT2 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The CVT VT2 transmission was released in 2009 and was offered to numerous carmakers (Brilliance/BYD/Chery/Geely Emgrand/Great Wall/Tengyi/Haima 3/Freema/Hyundai Avante HD hybrid/Huandong /Toyota Vitz).

CVT transmissions VT1 and VT2 have a reliable design (with a significant safety margin of transmission components) with a push belt. For many years, maintenance and repair services for this CVT are limited to change of oil and filter, and later – replacement of the Bosch belt.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	182	8	3,1	EZL-799-A45

The software of VT1,2 is designed to spare expensive cones at low speeds, when the belt and surfaces of cones operate very intensively. The cones have wear-resistant coating of operating surfaces implemented with the help of space technologies. These cones cannot be rebuilt and are not supplied to repair markets. The valve body filter in the VT2 transmission is based on Jatco solutions.

Rare overhauls accompanied by reassembly of spare parts, the wear of which leads to pressure losses on the friction clutches and their consequent wear, require the repair kit of gaskets and seals. Repair specialists prefer to use Precision repair kit.

Experienced transmission repair specialists, who work with VT1 and VT2 transmissions, change the filter and ATF as often as possible, because it is extremely hard to find spare parts for these transmissions. While changing the filter and ATF specialists usually check the chain (belt) for wear of the protector and in case of any suspicion of wear – replace the belt. The 30-40% wear of the belt teeth increases the risk slippage (metal-on-metal), even with the common (not sports) acceleration to outrun the truck ahead.

If the surfaces of cones have tears or "pits", then specialists advice to replace the CVT instead of its repair. Generally, the VT2 transmission is considered to be "invincible” under the condition of proper maintenance. Today, it is one of the best CVTs on the market.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Beijingauto	C51	15-16	CVT FWD	L4 1.5L
Beijingauto	D50	14-16	CVT FWD	L4 1.5L
BYD	F3	09-16	CVT FWD	L3 1.0L
BYD	G3	09-16	CVT FWD	L4 1.8L
BYD	L3	10-16	CVT FWD	L4 1.8L
Dongfeng	JOYEAR S50	15-16	CVT FWD	L4 1.6L
Emgrand	EC8	13	CVT FWD	L3 1.0L
Geely	EMGRAND EC7	09-16	CVT FWD	L4 1.3L 1.8L
Geely	EMGRAND EC7-RV	10-16	CVT FWD	L4 1.8L
Geely	GLEAGLE GC7	16	CVT FWD	L4 1.5L
GreatWall	M2	10-16	CVT FWD	L4 1.5L
GreatWall	VOLEEX C30	10-16	CVT FWD	L4 1.5L
Haima	FAMILY	07-16	CVT FWD	L4 1.6L
Haima	M3	13-16	CVT FWD	L4 1.5L
Haima	M5	14-16	CVT FWD	L4 1.5L 1.6L
Haima	M6	15-16	CVT FWD	L4 1.5L
Haima	PREMACY	09-16	CVT FWD	L4 1.6L 1.8L
Haima	S5	14-16	CVT FWD	L4 1.5L 1.6L
Jianghuai	HEYUE	14-16	CVT FWD	L3 1.0L
Jianghuai	HEYUE A30	14-16	CVT FWD	L4 1.5L
Jianghuai	HEYUE RS	14-16	CVT FWD	L3 1.0L
Jianghuai	REFINE S5	16	CVT FWD	L4 1.5L
Jianghuai	S3	14-16	CVT FWD	L4 1.5L
Proton	EXORA	09-16	CVT FWD	L4 1.6L
Proton	IRIZ	14-16	CVT FWD	L4 1.3L 1.6L
Proton	PREVE	12-16	CVT FWD	L4 1.6L
Proton	SAGA	11-16	CVT FWD	L4 1.3L 1.6L
Proton	SUPRIMA S	13-16	CVT FWD	L4 1.6L
Soueast	BOLANG	15-16	CVT FWD	L4 1.5L 2.0L
Soueast	V3	10-16	CVT FWD	L4 1.5L
Soueast	V5	12-16	CVT FWD	L4 1.5L
Soueast	V6	13-16	CVT FWD	L4 1.5L

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme VT2

0AW Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

8-speed CVT 0AW (VL380) was produced by Audi in 2004 for 4WD Audi models (from А3 (Sportback) to А7 (Sportback)) with gasoline engines from 1.8 to 3 liters to replace the 6-speed transmission 01J.

In 2007, the new modification of this transmission named VL381 was produced. This CVT inherited only few spare parts (friction elements, steel disc etc) and the operation principle from its predecessor 01J. Electric components and the valve body were significantly improved. This smart transmission can send a huge torque (for CVTs) - up to 400Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	CVT	FWD/AWD	400		5.5-7	G 052 516 A2

Technical issues and repair guidelines

There is still some old peculiarity of this transmission, which is related to the pulling chain – if the car equipped with this transmission is used for towing, then the cones with the chain get damaged without a chance for repair.

Parts for repair of the 0AW transmission (besides an internal filter) are quite rare and available on request. For example, one of the typical issues is burning of the clutch drum. The internal filter is the same as for VL380 and 381. Filters are produced for deep and small pans.The list of required spare parts also includes the belt, which should be replaced without waiting for the moment when very expensive cones may be damaged. The price of these cones is comparable with depreciation value of the vehicle itself.

The pulling belt gets stretched pretty fast because of extreme loads. Automakers give different figures regarding the belt service life before it should be replaced, but all of these figures are much lower than 200 thousand kilometers, therefore the belt is included in every second order for the overhaul of the 0AW transmission. In rare cases, it is necessary to replace a very expensive TCM (control unit) – valve channels of this control unit can be damaged by contaminated ATF.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A4	07-16	CVT FWD	L4 1.8L 2.0L V6 2.7L 3.0L 3.2L
Audi	A5	06-16	CVT FWD	L4 1.8L 2.0L V6 2.7L 3.0L 3.2L
Audi	A5 SPORTBACK	09-16	CVT FWD	L4 1.8L 2.0L V6 2.7L 3.0L
Audi	A6	11-16	CVT FWD	L4 2.0L V6 2.5L 2.8L 3.0L
Audi	A7	10-16	CVT FWD	V6 2.5L 2.8L 3.0L

How to repair this transmission (Videos)

DL501 Wet Dual Clutch

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme 0AW
web	workshop-manuals.com	Draining ATF and filling up after repairs
web	workshop-manuals.com	Removing and installing gearbox

TR80SD Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 8-speed 0С8 (or TR-80SD according to Aisin) is a new generation of Aisin RWD transmissions. It was designed in 2006 for VAG (Volkswagen-Audi) as an alternative to DSG, which still can not function reliably with powerful engines.

This transmission was installed on Audi Q7 equipped with diesel engines V6-V8 from 3 liter capacity, and the torque capacity over 700 Nm. The same trasnmission design adapted for off-road Lexus cars has been used since 2007 under the name AA80E\F.

In the winter of 2010, this 8-speed transmission fully entered the foreign market, where it replaced its 6-speed predecessor TR-60SN on Porsche Cayenne (2010 - 2014) and on Tuareс (2010 - 2014) in different sub-versions for TDI diesel engines with the capacity from 3.0 up to 3.6 liters (Audi -TFSI). This transmission was used by American automakers for Cadillac CTS VSport in 2014 under the name TL-80SD. The competitive model for above mentioned gearbox is ZF 8HP70. This transmission was designed with usage of successful TR60-SN elements, but the valve body and the overall construction of transmission components and electrics were significantly modified. Most of the parts are not interchangeable with the predecessor. It is the most powerful of modern RWD Aisin transmission capable of transmitting the torque up to 800 Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	AT	RWD/AWD	850	10,5	8	Toyota ATF WS

Technical issues and repair guidelines

This gearbox as all Aisin RWD transmissions is considered to be “invincible” and maintainable, designed to travel up to one million kilometers with minimum number of overhauls.

The repair kit of gaskets and seals is ordered for reassembly in order to restore leak resistance of jointing edges by replacement of rings and gaskets that helps to the valve body in regulation of gear shifting by the oil pressure. The whole kit of friction elements is replaced when some components get burned. At the same time, it is recommended to change the torque converter frictions in case of burned ATF.

For this transmission automakers used a new torque convertor with a multi-disc lockup clutch in order to guarantee a prolonged service life of torque converter frictions (over 200 thousand kilometers) and at the same time allow the driver to accelerate with the help of forced blocking of the torque converter lock-up clutch in "slippery mode". It significantly increases the transmission efficiency, improves acceleration characteristics, but wears out hard-working frictions of the lock-up. The valve body of this transmission differs from its predecessors TR-60 and TF-60. This valve body will get clogged if it is used with contaminated ATF for several years. Aisin solenoids in contrast to ZF solenoids can withstand much more open-close cycles.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	Q7	09-15	8 SP 4WD	V6 3.0L V8 4.2L
Porsche	CAYENNE	10-16	8 SP 4WD	V6 3.0L 3.6L V8 4.2L 4.8L
Porsche	PANAMERA	11-16	8 SP RWD	V6 3.0L
Volkswagen	TOUAREG	10-16	8 SP 4WD	V6 3.0L 3.6L V8 4.2L

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme TR80SD

JF009E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The constantly variable transmission (CVT) JF009E (RE0F08A) is constructed for the class "mini" and can be paired with engines up to 1800 cm3. In 2002, the RE0F08A unit replaced not very popular RE0F21A modification.

The JF009E transmission found application in various Nissan models, (1.8L Nissan Serena, March, Cube 2000-09, Micra 03-09. FIAT Punto, Palo, Uno 03-09...), but became more popular in Nissan Cube, Tiida and Wingroad. In terms of design, this CVT is similar to neighboring Jatco variators and comes between highly-demanded JF011E (for the middle class) and JF015E (for the class mini/micro). Many spare parts from the RE0F21A unit are interchangeable.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	175	8,3		CVT Fluid NS-2

Technical issues and repair guidelines

The main repair procedure for this invincible gearbox lies in fluid change and filter replacement. This CVT is sensitive to contaminated and cold transmission fluid. But in general, components of this CVT have an immense reserve for aggregated engines, serving for a long period of time even with contaminated fluid and clogged filters. The main coarse filter (made of metal with a mesh) is located in the pan and operates for a long period of time. This CVT also has an external fine filter, which is usually changed every 50-60 thousand kilometers. The reassembly includes spare parts replacement (Repair kit of gaskets and seals).

The design of this CVT family is developed for engines with a higher torque and has such a solid reserve of CVT components, that it gets in repair services when the car itself exhausts its resource, therefore repair procedures in these CVTs are so rare.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Nissan/Datsun	CUBE	08-16	CVT F/4WD	L4 1.5L
Nissan/Datsun	CUBE/CUBE CUBIC	02-12	CVT FWD	L4 1.4L 1.5L 1.8L
Nissan/Datsun	MARCH	06-12	CVT FWD	L3 0.9L
Nissan/Datsun	NOTE	05-12	CVT FWD	L4 1.5L
Nissan/Datsun	TIIDA/TIIDA LATIO	05-12	CVT FWD	L4 1.5L 1.8L
Nissan/Datsun	VERSA	06-13	CVT FWD	L4 1.8L
Nissan/Datsun	WINGROAD	05-16	CVT FWD	L4 1.5L 1.8L

How to repair this transmission (Videos)

RE0F08A JF009E valve body

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.es	Scheme JF009E
pdf	textfiles.com	Service manual RE0F08A

TW40E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission A174 (TW-40) belonging to the "micro" class with a rear drive was designed by Aisin in 1998 on the basis of 3-speed predecessor А172. After testing and update, this transmission was installed on Suzuki Jimni, Escudo, Avery (Landy) with engines from 0.7 up to 1.3 liters. This automatic transmission is considered to be a modern, economical and “invincible” unit for the minimum torque (up to 120 Nm). Americans had been using TW-40E on Ford Pronto with 3-cylinder liter engine until 2007.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD	120	3,7	2	Dexron III

Technical issues and repair guidelines

For reassembly of the A174 unit repair specialists order the repair kit of gaskets and seals, clean the valve body and replace spare parts, and rebuild the torque converter. Transmission experts assume that it is necessary to replace all friction clutches (soaked with oil combustion products) in transmissions operating with burnt oil.

The valve body design of this transmission includes "On-Off" solenoids (responsible for gear shifting and the torque converter lock-up operation), and a big EPC solenoid. Solenoids are adjusted quite accurately and ensure the torque converter actuation without a hard slippage. Therefore the torque converter does not overheat or smudge solenoids too much, allowing solenoids to operate for quite a long time. Sometimes problems occur in wiring of solenoids.

In the process of complete reassembly of А174/TW-40E, transmission specialists replace the following repair kits with the aim to prolong the operation period of the unit:

- Kit of steel discs TW-40E

- Kit of traversing pistons (6 pieces)

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chinamotor	VERYCA BUS	01-03	4 SP RWD	L4 1.2L
Mitsubishi	MINICAB VAN	99-16	4 SP R/4WD	L3 0.7L
Mitsubishi	PAJERO MINI	00-12	4 SP R/4WD	L4 0.7L
Proton	JUARA	00-04	4 SP RWD	L4 1.1L

6DCT150 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed 6DCT150 was developed by the company Dongfeng Getrag. It is considered to be the most space-saving dual-clutch gearbox worldwide. "Cascading Gears", implemented in this transmission, helped to reduce the total weight of the gearbox. Another feature called "Smart-Actuation” contributed to significant reduction of energy consumption. This transmission operates with engines, which have low torque. It is intended for compact and medium cars.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DCT	FWD		1,8	1,8	75w90

Technical characteristics of 6DCT150: wet clutch, 6 forward gears, 1 rear gear, maximum torque reaches up to 130-190 Nm (the most popular torque range for passenger cars). This transmission has undeniable technical advantages in its class. The 6DCT150 is notable for its efficiency, resistance to loads, great "efficiency / cost" ratio. When compared to traditional automatic transmissions, 6DCT150 ensures faster gear shifting.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dongfeng	A60	15-16	6 SP FWD	L4 1.4L
Dongfeng	AX3	15-16	6 SP FWD	L4 1.4L
Dongfeng	H30	16	6 SP FWD	L4 1.5L
Dongfeng	JOYEAR	16	6 SP FWD	L4 1.5L 1.6L
Dongfeng	JOYEAR S50	15-16	6 SP FWD	L4 1.4L 2.0L
Dongfeng	JOYEAR X5	16	6 SP FWD	L4 2.0L

How to repair this transmission (Videos)

Getrag 6DCT150

Instruction manuals and useful links

Link type	Source	Description
pdf	getrag.com	Technical data 6DCT150
pdf	getrag.com	Press information

P110 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TOYOTA ECVT P110 / P111 / P112 / P210 / P310 / P311 / P312 / P314 / P410 / P510

CVT-type automatic transmissions are produced by Aisin for hybrid cars Toyota and Lexus. These transmissions have an initial prefix “P” (it means that these transmissions belong to the planetary type). Some people mistakenly believe that the planetary gearbox cannot be a CVT, but it’s wrong. Planetary gearboxes (not all) have a metal chain (analog of a belt in CVT). Even Toyota considers these planetary gearboxes as CVTs and name them as eCVTs. Undoubtedly, the planetary gearbox differs from standard CVTs (on the global scale the planetary gearbox is not so complicated as CVT), but it is still CVT with its problems and repair peculiarities.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	ECVT	FWD				TOYOTA CVT FLUID FE

The first CVT of the planetary type eCVT (model P110) was manufactured in 1997 and was installed on the first generation of Toyota Prius for the domestic Japanese market. In 2000, this CVT was upgraded for Prius and was named as P111. Toyota Prius equipped with the P111 transmission was sold not only in Japan, but also in the US.

The new planetary CVT P112 was designed in 2001. This gearbox was intended for more powerful (2,4 liter engines) and heavyweight cars (Toyota Estima Hybrid and Toyota Alphard Hybrid). The planetary CVT transmission P112 found application in Toyota Prius, which was sold in Europe, Canada, and USA. The P112 actually became one of the most popular CVTs of planetary type.

The planetary CVT P310/Q211 (named as Q211 for Lexus) was manufactured in 2005. This transmission was specially developed for SUVs with FWD and 3.3-3.5 liter engines. This transmission was installed on hybrid cars Lexus RX400H, Toyota Kluger Hybrid.

The planetary CVT P311 was released in February 2006. It was intended for FWD cars with 2.4 liter engines. In comparison with P112, this gearbox is noted for reduced fuel consumption when the engine

has high RPM rates. In the same year, Aisin started production of the transmission P312 which was designed on the basis of P311. This transmission was supplied to Nissan Motor Company Co., Ltd (for application in Nissan Altima Hybrid in the US market. It was also installed on Toyota Harrier Hybrid 3,3 for the domestic market of Japan.

The eCVT P410 was launched in production in 2009. This transmission was developed for FWD cars equipped with 1.8 liter engines. Peculiarities of this transmission include transfer gear case assembly and possibility of smooth reduction of the engine speed at high RPM rates. This eCVT as well as P112 found application at a global scale, because it was installed on Toyota Prius, which had been sold from 2009 to 2015 all over the world. In addition, the P410 transmission was used for a new range of cars ( Toyota Prius Alpha, Toyota Prius V, and Lexus CT200H.

In July 2009, Aisin released a new modification of eCVT named as P311-03A. This transmission had an upgraded oil pump and engine cooling system. In 2010, Aisin started production of the P410 planetary CVT for plug-in hybrid vehicles.

In August 2011, Aisin started production of a new planetary CVT named P314 for 2,5 liter engines (for FWD and AWD). This transmission was equipped with a new oil pump, which ensured lower fuel consumption. According to Toyota plans, this transmission also should find a global scale application, because cars equipped with this transmission are sold all over the world (Toyota Camry Hybrid (for markets of the US and Japan), Lexus NX300H (for European market), and Toyota Rav4 Hybrid (for all global markets). The P314 eCVT is considered to be quite “new” and it is rarely found in repair services.

In November 2011, Aisin released a new eCVT transmission named as P510. This gearbox has a new design and operates with an NZ-series engines (engine capacity = 1.5 liters). The list of cars which use this transmission includes Toyota Corolla Hybrid, Toyota Yaris Hybrid, Toyota Prius C. The P510 transmission in noted for its light weight, small dimensions, and increased efficiency.

In January 2016, Aisin released a new eCVT P610. This gearbox was intended for application in a new generation of Toyota Prius.

Problems and repair procedures

Abrasive particles often damage oil pump of eCVT , in case of ill-timed ATF change.

1) The planetary gear set wear is often caused by abundance of metal shavings. It is especially common for planetary type CVTs P112 installed on Toyota Prius (produced in the 2003-2008 timeframe).

2) Repair services for eCVTs often include replacement of gaskets and seals (Overhaul kits), pump seal, axle shaft oil seal.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Toyota	PRIUS	0	EVT FWD	L4 1.5L

K110 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TOYOTA K110 / K111 / K111F / K112 / K112F / K114

The first generation of CVT transmissions designed by the Japanese company Aisin was produced in August of 2000. Initially, the CVT K110 was designed for FWD cars with the engine capacity of 2 liters. According to many sources, Toyota (co-founder and co-owner of Aisin) combined the license (bought from Jatco) and its own developments in the field of CVTs (the first CVT named as P110 was successfully tested by Toyota on Toyota Prius with the body NHW10 for the domestic Japanese market).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		8	5	Aisin CVTF7004, Toyota 08886-02105

Technical issues and repair guidelines

The first car with the K110 CVT was Toyota Opa, 2.0 (2000-2005), which was sold exclusively in the domestic market of Japan. A year later (in 2011) the K110 transmission was installed on sedans Toyota Alion/Toyota Premio and minivans Toyota Voxy/Toyota Noah/Toyota Estima, etc. All these right-hand drive cars were originally intended for sale at the domestic market of Japan as well as in some Asian countries. For 4 years of production, Toyota managed to fix some standard issues related to this CVT. In 2004, Toyota released an improved version of K110 which was named as K111/K111F (prefix “F” means that this CVT is intended for all-wheel drive vehicles).

The K111 transmission was designed on the basis of K110, and these two transmissions are very similar in terms of technical solutions. The K111 transmission (in contrast with K110) has a new belt as well as linear control over the N gear and acceleration. It has a positive impact on fuel efficiency and transmission performance characteristics.

For some time, Toyota was actually “catching up” with other Japanese companies in terms of CVT application. Therefore, Aisin (which produced CVTs for Toyota) had to use spare parts of different manufacturers for assembly of K110 and K111. Moreover, Aisin heavily depended on third-party suppliers and on quality of supplied spare parts. For example, belts for Aisin CVTs were produced by the German company Bosch. Toyota didn’t want to put up with such state of affairs. The Japanese auto giant wanted (via its subsidiary Aisin) not only to fully control the whole process of transmission production, but also to develop and introduce new CVT technologies. Thus, in 2002, Aisin jointly with Bosch established a joint company Shivutech Co., Ltd. (trade mark CVTEC). The purpose of this company was the development and production of components for CVTs. Three years later in 2005, CVTEC developed the belt for a new type of CVT.

According to the original technology, this new push belt consists of thin steel sheets with high-precision gaps (equal to several microns). This solution ensures high strength of belt elements. In addition, the durability of this belt was enhanced by the sandblasting procedure. These measures made it possible to launch in production a new series of CVTs K112/K112F in October of 2005. These CVTs with higher torque transmission capacity were initially intended for coupling with 2,4-liter engines. The first car equipped with the K112/K112F transmission was Toyota Rav4. Later this CVT was applied in Toyota Estima, Toyota Blade, Toyota Vellfire and many other cars.

Typical problems in K110/K111/K112

Transmission specialists often have to deal damage of bearings on the input shaft of K111 and K112. This problem may be caused by production defects or contaminated ATF with metal shavings. These metal shavings reach the bearing via a small hole in the gearwheel. As a result, balls in the bearing become cemented leading to its wear. Over time, the “dying” bearing damages the gear-wheel itself

If K110 / K111 / K112 transmissions get overheated (ATF has a “burning” smell), then it may lead to replacement of the complete set of friction clutches. In this case, transmission specialists also replace gaskets, rings, and seals (the reason is simple – rubber hardens affected by temperature and becomes less flexible; eventually, it leads to oil leakages. Long-term usage of the car with worn friction clutches and rings leads to overheating of pistons and their consequent replacement.

Acceleration from rest with the cold CVT (in winter time) leads to curving of the CVT belt on cones (on minimum radius). At the same time, the belt touches cones on the minimum area. It often leads to the belt slippage (with cold ATF). In this case, the belt wears down and scratches cones. With time surfaces of cones will have tears. The belt slippage also will have a negative impact on solenoid-operated valves.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Toyota	ALLION	01-16	CVT FWD	L4 2.0L
Toyota	ALPHARD	03-12	CVT F/4WD	L4 2.4L
Toyota	COROLLA	14-16	CVT FWD	L4 2.0L
Toyota	NAV1	12-16	CVT FWD	L4 2.0L
Toyota	OPA	00-05	CVT FWD	L4 2.0L
Toyota	PREMIO	01-16	CVT FWD	L4 2.0L
Toyota	WISH	03-16	CVT FWD	L4 2.0L

JF414E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission JF414 of the class “mini” with an east-west mounting for FWD cars was designed by the Japanese company Jatco for vehicles with the engine capacity of up to 1.6 liters. AvtoVaz used JF414 for Lada "Granta".

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		7	3	Matic-S

Technical issues and repair guidelines

Besides Lada Granta, this CVT transmission was also installed on Nissan Almera and March models with up to 1.6 liters. Moreover, this solution may be used on Ad Van. This CVT was developed as a budgetary and reliable option for "long-running" cars. The main competitor of this CVT is AW60-40 by Aisin.The design of JF414E components is maximally simplified according to the principle "nothing in excess"

Repair procedures and typical problems

Rebuilding procedures of this transmission are related to the replacement of spare parts (namely, gaskets, seals and friction elements).Usually repair specialists have to replace worn-out friction elements. Bearings also may be replaced in the course of the overhaul. The most common bearing to be replaced is a double-row center bearing. This bearing is damaged by overloads and driving with vibrations at high speeds.The valve body of the JF414 unit is quite reliable and rarely gets replaced.

The main spare parts of the valve body are gaskets and solenoids. The transmission exploitation with contaminated fluid, worn-out torque converter clutch, and especially overheating may shorten the service life of solenoids and valve body gaskets by several times. The list of vulnerabilities of Jatco valve bodies includes sensors and a circuit board located in the valve body. Also these valve bodies are very sensitive to contaminated and hot fluid with metal chips.Computer settings are well-adjusted for packages and the torque converter lockup, which turns on at the very end of the 3-rd and 4-th gear, allowing the friction to have quite a long service life.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LADA	GRANTA	12-16	4 SP FWD	L4 1.6L
LADA	KALINA	13-16	4 SP FWD	L4 1.6L
LADA	PRIORA	12-16	4 SP FWD	L4 1.6L
Nissan/Datsun	MARCH	10-16	4 SP FWD	L3 0.9L 1.2L L4 1.5L
Nissan/Datsun	MI-DO	15-16	4 SP FWD	L4 1.6L
Nissan/Datsun	ON-DO	14-16	4 SP FWD	L4 1.6L
Suzuki	SWIFT	11-16	4 SP FWD	L4 1.4L

Instruction manuals and useful links

Link type	Source	Description
web	transakpp.ru	Scheme

725.0 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 9-speed automatic transmission 9G-Tronic (725.0) was developed by the company Mercedes-Benz and was released in 2013, replacing the model 7G-Tronic.

When developing this gearbox, Mercedes-Benz’s transmission specialists concentrated on simplifying the structure of the transmission, while maintaining its size and implementing the solution with 9 gears, minimum number of planetary gear sets and mechanisms of gear shifting. As a result of intensive computer system analysis and synthesis, transmission engineers solved this problem by means of only 4 planetary gear sets and 6 gear shifting mechanisms.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
9	AT	RWD/AWD	1000	10,2	6	236.16

Since 2014, the 9G-Tronic transmission has been installed on cars of E-(including coupe/cabriolet) and CLS Classes, since 2015 – on GLC, GLE (including coupe), and GLS Classes. The 9G-Tronic is considered to be the world’s first 9-speed automatic gearbox in the segment of premium cars. The performance efficiency of this amounts to incredible 92% (this parameter of 7G-Tronic was equal to 85%). The span of gear ratios is equal to 9.15.

Despite two additional gears and the maximum torque up to 1000 Nm, 9G-Tronic requires the same amount of space for positioning as its predecessor. Three speed sensors monitor the operation of the gearbox and provide the TCU with relevant information for efficient gear shifting. Three different modes of operation allow the driver to pre-select an appropriate algorithm of gear shifting. It improves driving comfort and reduces the noise level.

The 9G-Tronic transmission has 3 driving modes:

«Comfort» («C») — for driving with low fuel consumption;

«Sport» («S») — for fast driving style at high engine RPM;

«Manual» («M») — for fast driving and manual gear shifting via the system DIRECT SELECT.

According to representatives of Mercedes-Benz, this transmission is suitable for cars with rear and all-wheel drive, as well as for hybrids and E-motors.

MERCEDES BENZ C CLASS L4 1.6L 2.0L 2.2L
MERCEDES BENZ CLS L4 2.2L V6 3.5L
MERCEDES BENZ E-CLASS L4 2.0L 2.2L V6 3.0L 3.5L
MERCEDES BENZ E-CLASS COUPE L4 2.2L
MERCEDES BENZ GLC L4 1.6L 2.0L 2.2L V6 3.0L 3.5L
MERCEDES BENZ GLC COUPE L4 2.0L 2.2L V6 3.0L
MERCEDES BENZ GLE COUPE V6 3.0L
MERCEDES BENZ S CLASS V6 3.0L 3.5L

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	E-CLASS	16	9 SP RWD	L4 2.0L
Mercedes-Benz	GLC COUPE	16	9 SP 4WD	L4 2.2L

How to repair this transmission (Videos)

9G-Tronic transmission. Maintenance

725 0 Diagnosis of shift quality

9G-TRONIC (Gesamtsystem)

Instruction manuals and useful links

Link type	Source	Description
pdf	epfl.ch	System description 725.0
web	Wikipedia	Mercedes-Benz 9G-Tronic transmission
web	car-engineer.com	9G-TRONIC automatic transmission

724.2 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In the fall of 2010, engineers of Mercedes-Benz presented an updated version of the automatic gearbox 7G-Tronic Plus. For the first time this gearbox was applied in the CL-class (216 series). According to representatives of the company, this gearbox became more comfortable, quick-operating and economical than its predecessor. The 724.2 gearbox is equipped with the torque converter of a new generation. This torque converter is more durable; it has reduced noise level and faster response time thanks to innovative technology. In addition, this gearbox is equipped with the “start-stop” system. The engine RPM gets reduced in the ECO mode that significantly contributes to fuel economy.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	Hybrid System	RWD		9,5		236.15

The 724.2 gearbox undergone systematic optimizations to reduce energy losses caused by traction. This and other measures made it possible achieve 7% fuel economy. In 2012 a new car Mercedes-Benz SL was equipped with the 7G-Tronic Plus. The roadster became the first car of Mercedes-Benz, which was equipped with a newly developed Direct Select paddle shifter on the centre console. This feature is used for more dynamic driving style. The latest changes in 7G-Tronic Plus were introduced in 2013. The updated version of this gearbox was used in E300 BlueTEC HYBRID, where the 20 kW e-motor was integrated in the case of the torque converter. In 2013 the 7G-Tronic was replaced by the 9G-Tronic automatic gearbox.

Peculiarities:

- 7-forward gears: increased difference between gear ratios of lowest and highest gears, while maintaining small intervals between gear ratios in other gears, increases driving comfort.

- Optimal engine RPM contributed to low fuel consumption and smooth gear shifting.

- Solid power reserve: fast accelerations became possible thanks to reverse gear shifting with omitting of several gears;

- New generation torque converter: reduced wear, lower noise level and better responsiveness thanks to innovative technology.

- Reduced fuel consumption: the function “Start-Stop ECO” ensures that the engine switches off temporarily when the car gets stick in traffic jams of stops at traffic lights.

- Comfort and sportiness: drivers can choose from 3 operation modes: «E» (Economy) – to reduce fuel consumption, «S» (Sport) – for sporty driving style, «М» (Manual) – for rapid gear shifting with the help of paddle shifters.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	C-CLASS	14-16	7 SP R/4WD	L4 2.0L 2.2L
Mercedes-Benz	C-CLASS COUPE	15-16	7 SP RWD	L4 2.0L 2.2L
Mercedes-Benz	E-CLASS	12-16	7 SP RWD	L4 2.2L V6 3.5L
Mercedes-Benz	GLC	15-16	7 SP 4WD	L4 2.0L 2.2L
Mercedes-Benz	ML-CLASS	15-16	7 SP 4WD	V6 3.0L
Mercedes-Benz	S-CLASS	09-16	7 SP RWD	L4 2.2L V6 3.0L 3.5L
Mercedes-Benz	S-CLASS COUPE	15-16	7 SP RWD	V6 3.0L
Mercedes-Benz	SPRINTER	13-16	7 SP RWD	L4 2.2L

How to repair this transmission (Videos)

7G-TRONIC Plus Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	europeantransmissions.com	7G-TRONIC PLUS

DQ500 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

DQ500 7-speed version DSG with a wet clutch for front-wheel drive was produced in 2009. This is a new generation of “wet” DSG for VW (Golf, Tiguan, Transporter) and Audi (A3, Q3) with TDI engines (with capacity equal to 2.0 and 2.5 l.).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DSG	FWD/AWD	600	7,6	6	G052182

Technical issues and repair guidelines

DQ500 (0BH\0BT) gearbox is sensitive to overheating and has a solid heat exchanger which may be clogged after 3-5 years of intensive operation. Therefore it requires washing during reassembly or replacement of the heat exchanger. The competitive gearbox is 09K by Aisin.This gearbox has some critical issues with Mechatronics which get clogged with dirt from the clutch cover.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A3	11-16	7 SP 4WD	L5 2.5L
Audi	Q3	11-16	7 SP F/4WD	L4 2.0L L5 2.5L
Audi	TT	09-16	7 SP 4WD	L5 2.5L
Skoda	SUPERB	15-16	7 SP 4WD	L4 2.0L
Volkswagen	CROSSBLUE	16	7 SP F/4WD	L4 2.0L V6 2.5L
Volkswagen	GOLF	14-16	7 SP F/4WD	L4 2.0L
Volkswagen	PASSAT	14-16	7 SP 4WD	L4 2.0L
Volkswagen	SCIROCCO	10-11	7 SP FWD	L4 2.0L
Volkswagen	SHARAN	11	7 SP FWD	L4 2.0L
Volkswagen	TIGUAN	10-16	7 SP F/4WD	L4 1.8L 2.0L
Volkswagen	TRANSPORTER	09-16	7 SP F/4WD	L4 2.0L

How to repair this transmission (Videos)

How to change oil

DQ250 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed DSG gearbox DQ250 - 02E (S-tronic) with a dual wet clutch was firstly used in 2003 in cars with engine capacity from 1.6 up to 3.2 l. VW started to install this gearbox serially on a number of vehicles (GOLF, JETTA, PASSAT etc). Expensive models of Seat and Scoda also were equipped with this gearbox. This gearbox is capable of transmitting quite high torque (up to 350 Nm). The structural design of this robotic transmission was created by VAG specialists jointly with the company "BorgWarner". Later this project was joined by the company "Luk".

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DSG	FWD/AWD	350	6,9	5,5	G052182

Technical issues and repair guidelines

Generally, these gearboxes serve quite reliably for 2-5 years. The warranty of the automaker has been extended (only VW) up to five years. At this period the percentage of visitors to service centers is still quite high. Customers complain about the issues related to vibrations, kicks, jerking caused by the double-disk clutch, velocity sensors, chips in the gearbox that damage mechatronics.

First repairs of these sophisticated and highly-priced gearboxes are related to replacement of filters: external filters of heat exchanger and ATF, which should be changed with the external filter. Minor and repeated repair operations of DQ250 involve replacement of VFS solenoids, which get damaged by dirt from ATF and, as a result, lose their operating qualities related to changing the oil flow and its pressure. As a result, VFS solenoids become "rejected" by the control system. The reassembly of 02E -DQ250 gearbox with the replacement of rings, seals and filters is “a must” procedure to prolong the lifespan of its friction elements and solenoids.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A3	03-16	6 SP F/4WD	L4 1.8L 2.0L
Audi	Q3	13-16	6 SP F/4WD	L4 1.4L 2.0L
Audi	TT	98-16	6 SP F/4WD	L4 1.8L 2.0L V6 3.2L
Seat	ALHAMBRA	10-16	6 SP FWD	L4 1.4L 1.8L 2.0L
Seat	ALTEA	04-15	6 SP F/4WD	L4 1.9L 2.0L
Seat	LEON	05-16	6 SP FWD	L4 2.0L
Seat	TOLEDO	05-08	6 SP FWD	L4 1.8L 2.0L
Skoda	LAURA	05-13	6 SP FWD	L4 1.9L 2.0L
Skoda	OCTAVIA	04-16	6 SP F/4WD	L4 1.8L 2.0L
Skoda	SUPERB	08-16	6 SP F/4WD	L4 1.4L 1.8L 2.0L V6 3.6L
Skoda	YETI	09-16	6 SP 4WD	L4 1.8L 2.0L
Volkswagen	CADDY	04-16	6 SP F/4WD	L4 1.9L 2.0L
Volkswagen	CC	08-16	6 SP F/4WD	L4 2.0L V6 3.0L 3.6L
Volkswagen	EOS	06-15	6 SP FWD	L4 1.6L 2.0L V6 3.2L 3.6L
Volkswagen	GOLF	04-16	6 SP F/4WD	L4 1.4L 1.8L 2.0L
Volkswagen	GOLF PLUS	05-14	6 SP FWD	L4 2.0L
Volkswagen	GOLF SPORTSVAN	14-16	6 SP FWD	L4 2.0L
Volkswagen	JETTA	05-16	6 SP FWD	L4 1.6L 1.9L 2.0L L5 2.5L
Volkswagen	MAGOTAN	11-16	6 SP FWD	L4 1.8L 2.0L V6 3.0L
Volkswagen	NEW BEETLE	11-16	6 SP FWD	L4 2.0L
Volkswagen	PASSAT	05-16	6 SP F/4WD	L4 1.8L 2.0L V6 3.0L 3.2L 3.6L
Volkswagen	POLO	14-16	6 SP FWD	L4 2.0L
Volkswagen	SCIROCCO	08-16	6 SP FWD	L4 1.6L 1.8L 2.0L
Volkswagen	SHARAN	10-16	6 SP FWD	L4 1.4L 1.8L 2.0L
Volkswagen	TIGUAN	08-16	6 SP F/4WD	L4 1.4L 2.0L
Volkswagen	TOURAN	05-16	6 SP FWD	L4 1.4L 1.6L 1.8L 2.0L
Volkswagen	VENTO	14-16	6 SP FWD	L4 1.5L

How to repair this transmission (Videos)

Clutch Replace

VW Mechatronic Unit - DSG DQ250 02E

02E DSG Clutch Damage

VW and Audi DSG Clutch Upgrade

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Self-study programme 308 DQ250 02E
pdf	www.at-manuals.com	The 02E Direct Shift Gearbox Design and Function DQ250
web	www.at-manuals.com	Solenoids and pressure control valve locations and functions DQ250
pdf	www.at-manuals.com	Design and Function 02E DQ250

DQ200 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This dual-clutch transmission is controlled with the use of electric motors instead of hydraulic valves of piston valves and the pump.This transmission uses the main tested advantage of mechanical gearboxes – the clutch is relocated to open space and wear products of clutches are immediately get out from the transmission without causing any harm. Neither planetary gears nor hydraulic switch control are used for this purpose.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DSG	FWD	250	1,7	1,7	G052512

Technical issues and repair guidelines

Gear shifting is implemented by two fork connectors controlled from a closed small hydraulic Mechatronic which may contain approx. 1 liter of ATF. This immediately reduced the cost of production at the expense of the transmission resource. Such transmissions cover 200 thousand kilometers with some problems. But at the same time advantages of this transmission are very attractive (high level of efficiency (up to 97%) and dynamics).

Repair and typical problems of DQ200

These transmissions are quite complex for repair, therefore replacement is more preferable option.

The most common problems are related to all new elements:

- The dual-clutch gets worn out early or unevenly in case of an aggressive driving style.

- The new electric oil pump breaks too early and frequently and operates in an abnormal fashion.

- Typical issues with operation of sensors.

- High oil pressure in Mechatronics units push out the oil with fatal consequences for the trasmission.

As a result, automakers had to modify the transmission and some separate units each 2-3 years, investing more and more financial resources in making the transmission more sophisticated and expensive and hope that the project DSG will pay off before releasing of 1 million transmissions. The most common problem that occurs in these transmissions (except clutches vibrations): damage of the shifting fork Reverse\6 (including bearing parts).

There are also different defects successfully fixed in services specialized in repairing DSG with a dry clutch. The repair process related to components of this transmission is quite complicated and therefore this option doesn’t have much support among car owners, especially when the engine resource comes to an end.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A1	10-16	7 SP FWD	L3 1.4L L4 1.4L 1.6L 1.8L
Audi	A3	07-16	7 SP FWD	L3 1.0L L4 1.2L 1.4L 1.6L 1.8L
Audi	Q1	16	7 SP FWD	L3 1.0L 1.4L L4 1.4L 1.6L
Audi	TT	11-16	7 SP FWD	L4 1.8L
Seat	ALTEA	08-15	7 SP FWD	L4 1.6L 1.8L
Seat	IBIZA	08-16	7 SP FWD	L4 1.2L 1.4L 1.6L
Seat	LEON	07-16	7 SP FWD	L3 1.0L L4 1.2L 1.4L 1.6L 1.8L
Seat	TOLEDO	12-16	7 SP FWD	L3 1.4L L4 1.4L 1.6L
Skoda	FABIA	10-16	7 SP FWD	L3 1.4L L4 1.2L 1.4L 1.6L
Skoda	OCTAVIA	08-16	7 SP FWD	L4 1.2L 1.4L 1.6L 1.8L
Skoda	RAPID	12-16	7 SP FWD	L3 1.0L L4 1.2L 1.4L 1.5L 1.6L
Skoda	RAPID SPACEBACK	13-16	7 SP FWD	L4 1.2L 1.4L 1.6L
Skoda	ROOMSTER	10-16	7 SP FWD	L4 1.2L 1.6L
Skoda	SUPERB	08-16	7 SP FWD	L4 1.4L 1.8L
Skoda	YETI	09-16	7 SP FWD	L4 1.2L 1.4L 1.8L
Volkswagen	BORA	10-16	7 SP FWD	L4 1.4L
Volkswagen	CADDY	10-16	7 SP FWD	L3 1.0L L4 1.4L 1.6L 2.0L
Volkswagen	CC	08-16	7 SP FWD	L4 1.4L 1.8L
Volkswagen	CROSS LAVIDA	14-16	7 SP FWD	L4 1.4L
Volkswagen	GOLF	07-16	7 SP FWD	L3 1.0L L4 1.2L 1.4L 1.6L
Volkswagen	GOLF PLUS	07-14	7 SP FWD	L4 1.2L 1.4L 1.6L 1.9L L5 2.5L
Volkswagen	GOLF SPORTSVAN	14-16	7 SP FWD	L4 1.2L 1.4L 1.6L
Volkswagen	GRAN LAVIDA	13-16	7 SP FWD	L4 1.4L
Volkswagen	GRAN SANTANA	15-16	7 SP FWD	L4 1.4L
Volkswagen	JETTA	08-16	7 SP FWD	L4 1.4L 1.6L 1.8L 1.9L 2.0L
Volkswagen	LAMANDO	14-16	7 SP FWD	L4 1.4L
Volkswagen	LAVIDA	09-16	7 SP FWD	L4 1.2L 1.4L 1.6L
Volkswagen	MAGOTAN	11-16	7 SP FWD	L4 1.4L 1.8L
Volkswagen	NEW BEETLE	11-16	7 SP FWD	L4 1.2L 1.4L 1.6L
Volkswagen	PASSAT	08-16	7 SP FWD	L4 1.4L 1.6L 1.8L
Volkswagen	POLO	07-16	7 SP FWD	L3 1.0L L4 1.2L 1.4L 1.6L 1.8L 2.0L
Volkswagen	SAGITAR	09-16	7 SP FWD	L4 1.4L
Volkswagen	SANTANA	14-16	7 SP FWD	L4 1.4L
Volkswagen	SCIROCCO	08-16	7 SP FWD	L4 1.4L
Volkswagen	SHARAN	10-11	7 SP FWD	L4 1.4L 1.8L
Volkswagen	TIGUAN	11-12	7 SP FWD	L4 1.4L 1.8L
Volkswagen	TOURAN	08-16	7 SP FWD	L4 1.4L 1.6L
Volkswagen	UP	14-16	7 SP FWD	L3 1.0L
Volkswagen	VENTO	13-16	7 SP FWD	L4 1.2L
Volkswagen	XL1	13-15	7 SP FWD	L2 0.8L

How to repair this transmission (Videos)

DSG7 P17BF error code solution from KINERGO

DQ200 Clutch Disassembly

Volkswagen improvements on clutch and mechatronic

DSG mehatronics replacement

DL501 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The rear-driven model of 7-speed DSG7 with "wet" clutch - DL501 has been installed on Audi Q5-Q7, A4 Allroad, A5 Cabriolet, A6-A7 since 2008. This gearbox is also named as OB5. It operates with engines up to V8 4.0l (diesel) and transmits the torque up to 550 Nm at maximum speed.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DCT	FWD/AWD	550	7,5	6,7	G 052 529 A2

Technical issues and repair guidelines

VAG DL501 (0B5) gearbox is structurally divided into two compartments - "mechanical" where the hypoid oil is used for mechanical gearboxes, and an "automatic" part with double clutch frictions and the valve body, where "intelligent" oil is used specially for DL501 - G 052 529 A2.

Typical problems

Chips from the drum harm both the filter and components of the gearbox, and the electrics. All gearboxes including 7-speed DL501 have issues with Mechatronics.The gearbox operation with metal chips in oil leads to rapid wear-out of solenoids. As far as the hardware of this gearbox is concerned, the main component to be replaced is the whole clutch drum.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A4	07-16	7 SP 4WD	L4 2.0L V6 3.0L V8 4.2L
Audi	A5	08-16	7 SP 4WD	L4 2.0L V6 3.0L 3.2L V8 4.2L
Audi	A5 SPORTBACK	09-16	7 SP 4WD	L4 2.0L V6 3.0L 3.2L
Audi	A6	11-16	7 SP F/4WD	L4 2.0L V6 2.8L 3.0L V8 4.0L
Audi	A7	10-16	7 SP F/4WD	L4 2.0L V6 2.5L 2.8L 3.0L V8 4.0L
Audi	Q5	08-16	7 SP 4WD	L4 2.0L V6 3.0L 3.2L
Porsche	MACAN	14-16	7 SP 4WD	L4 2.0L V6 3.0L 3.6L

How to repair this transmission (Videos)

DL501 Wet Dual Clutch

D6GF1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automated transmission HYUNDAI-KIA D6GF1 has been produced since 2012. In fact, this transmission is adaptation of the automated transmission produced by LuK. This transmission is coupled with 2.0 liter engines. The maximum torque transmitting capacity reaches up to 270 Nm. This transmission was mainly installed in Kia Ceed JD (2012-2018).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DCT	FWD	270	1,9	1,9	SAE 75W/85, API GL-4

Main problems:

- For some time after its release, the transmission had some malfunctions, but these issues were fixed;

- Manu drivers complain about jerks and delays while shifting gears;

- Some drivers had to deal with failures of even or odd gears;

- Sometimes the transmission gets stuck on some particular gear and fails to shift;

- Some car owners had to replace the clutch when the mileage reached 50 thousand kilometers;

- Price of original spare parts for this transmission is very high

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	VELOSTER	11-16	6 SP FWD	L4 1.6L
KIA	CEE'D	12-16	6 SP FWD	L4 1.6L

How to repair this transmission (Videos)

Kia Ceed 2012 Kia DCT

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme D6GF1
web	hvmanual.com	Specifications D6GF1

CFT23 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The constantly variable transmission (CVT) ZF CFT23 of the German manufacturer of auomatic transmissions with the trade name "Ecotronic" has been installed on Ford Focus, C-MAX with engines 1.6 - 1.8 liters since 2003 until 2008. Later more powerful CFT30 was developed for Ford vehicles with a 3-liter engine. This CVT had been installed before 2008 on powerful Taurus as well as on Ford Focus of European assembly. This CVT was also noticed on Mercury Sable. The “push” belt construction is used in СFT23 as in RE0F09A, /JF010E by Nissan instead of “pulling” belt used in 01J CVT (Audi).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	170	8,9		WSS-M2C928-A

Technical issues and repair guidelines

But in more powerful CFT30 the belt did not cope with loads (similar to problems of Nissan Murano), therefore the pulling belt was applied here as in the variator 01J.

Original spare parts for repair of these CVT (produced by ZF) are basically neither produced nor sold. It is almost impossible to get even used spare parts for repair of CFT. Therefore the most popular spare parts for repair of CVT CFT23 are filter and repair kit of gaskets and seals. Experienced specialists in repair services recommend to change the whole kit of rubber gaskets and seals as well as filter and oil without waiting for problems with surfaces of cones after 3-4 years of intensive operation. The belt is produced by only one company and similar to other CVTs with pushing belt. Friction clutches F and steel discs used in this transmission are the same as for ZF 5HP24/30/19.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	FOCUS	04-08	CVT FWD	L4 1.6L 1.8L
Ford	FOCUS C-MAX	04-08	CVT FWD	L4 1.6L 1.8L

How to repair this transmission (Videos)

CFT30 Rebuild

CFT30

cft30 cft23

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout CFT30
pdf	Sonnax	Vacuum test CFT30

BVLA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

BVLA is 5-speed automatic transmission produced by Honda. This transmission is often installed in Honda Pilot.

Honda Pilot; 05-07; V6 3.5L (J35Z4); ATF Capacity/Change: 8.7/8.3 3.9/3.7

BVLA transmission may have some problems in case of accelerations higher than 160 km/h, especially when dealing with poor road surface. This problem may lead to the overheating or oil starvation. Transmission specialists recommend warming up transmission before driving, including summer-time, monitor the oil level and timely perform diagnostic checks.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	PILOT	6	5 SP FWD	V6 3.5L

U440E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The U440E unit was designed by Aisin Co in 1999 for small FWD cars Toyota Yariz, Witz and Corolla with 1.3-liter capacity, which replaced the AW60-40 unit. This gear shifting solution usually can be found on the Japanese market of right-hand drive vehicles. The U340 unit produced simultaneously with U440E was chosen by Toyota for Corolla with the engine capacity of 1.5 liters and higher. The U540E unit more known as AQ4 is a quite rare solution for Daihatsu with more simple complete set. This gearbox is also used for American small cars Cadillac, Buick, Ford and Chinese Donfeng, Landwind under names AW80-40LS and AW81-40LS.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	150	5,8	2,1	Toyota Type T-IV

Technical issues and repair guidelines

The repair of this transmission is usually performed for cars with high mileage and already worn-out torque converter lockup unit. Each 4-th case of the rebuilding of this robust unit requires MasterKit – complete kit of spare parts. After the exhaustion of resource of this transmission (and rings wear-out), the first component to be worn is a set of frictions with steel discs in the clutch package Direct. After that, С1 Forward and Overdrive frictions get worn and then others.

The "soft spot" of AW81-40 components is considered to be the planetary gear, which even during testing required some servicing before covering 100 thousand kilometers. The reason is related to design issues. The transmission of maximum operating torque via the gear to the differential by means of strong side loads leads to the damage of units in this package. (Only paired with 1.6 liter engines). The major wear-out of friction units and consequent damage of the pump bushing takes place when neglecting the oil pressure parameters and wear-out of the torque converter.

As for electrical components, standard cleaning and valve body reassembly, repair specialists order EPC and On-Off solenoids. Sometimes the differential is also ordered for the overhaul. In old cars, specialist often install external fine filter. The filter helps to preserve clean ATF and decreases wear-out of friction components.

The spare parts resource will be significantly increased, if ATF is kept clean and the torque converter gets repaired after covering 150- 200 thousand kilometers (depending on the car type and driving style) and preventive cleaning of the valve body and solenoids. More often problems occur in cars with engines capacity equal to 1.3. The torque of these engines turns out to be too high for this automatic unit and electronic control allows the driver to load the transmission to the maximum. Careful usage of cars with this gearbox without fast accelerations from traffic lights and slipping on deep snow allows postponing first overhauls of this “invincible” gearbox for 6 or more years.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Beijingauto	E-SERIES	12-16	4 SP FWD	L4 1.3L 1.5L
Changan	CD101	12	4 SP FWD	L4 2.0L
Changan	CX20	10-16	4 SP FWD	L4 1.3L
Changan	JOICE	07-12	4 SP FWD	L4 1.6L 2.0L
Changan	V805	10-12	4 SP FWD	L4 1.6L
Changan	YUEXIANG	09-14	4 SP FWD	L4 1.5L
Changan	YUEXIANG V5	12-16	4 SP FWD	L4 1.5L
Changan	Z-SHINE	08-12	4 SP FWD	L4 1.5L 1.6L 1.8L 2.0L
Dongfeng	A30	14-16	4 SP FWD	L4 1.5L
Dongfeng	BFX	11	4 SP FWD	L4 1.6L
Dongfeng	H30	10-16	4 SP FWD	L4 1.5L 1.6L
Dongfeng	JOYEAR	16	4 SP FWD	L4 1.5L
Dongfeng	S30	09-16	4 SP FWD	L4 1.5L 1.6L
Ford	FIESTA	97-16	4 SP FWD	L4 1.6L
Ford	FUSION	06-12	4 SP F/4WD	L4 1.6L
Gonow	E MEI	14-16	4 SP FWD	L4 1.6L
Land-Wind	B102 HB / B103 NB	11-12	4 SP FWD	L4 1.6L
Land-Wind	E101	11-12	4 SP FWD	L4 2.0L
Land-Wind	FENGSHANG	06-10	4 SP FWD	L4 2.0L
Opel / Vauxhall	AGILA	08-14	4 SP FWD	L3 1.0L L4 1.2L
Suzuki	ALTO	15-16	4 SP FWD	L3 1.0L
Suzuki	BALENO	00-08	4 SP FWD	L4 1.5L
Suzuki	SPLASH	08-14	4 SP FWD	L4 1.2L
Suzuki	SWIFT	97-16	4 SP FWD	L4 1.2L 1.3L 1.4L 1.5L 1.6L
Toyota	YARIS	12-13	4 SP FWD	L4 1.5L

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme U440E
web	www.at-manuals.com	Check Balls U440E
web	www.at-manuals.com	Stall test U440E

AW45043LE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The rare 4-speed automatic transmission AW450-43LE had been installed since 1998 until 2007 on the RWD model ISUZU NPR/ NQR. with engines capacity of appr. 5 liters. In terms of design, this transmission is similar to AW442F. In most cases Isuzu models come to repair shops with the purpose of fixing the transmission.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		12,5	6	Type T-IV

Technical issues and repair guidelines

This transmission for RWD vehicles is very reliable as all Aisin transmissions with high torque capacity. In most cases, problems occur in old vehicles and mainly associated with their age. If the car owner keeps track of the thermostat condition, then the lifespan of the automatic transmission AW450-43LE can exceed the service life of the car itself.

The torque converter is the first component to get out of order in this transmission, then it leads problems with the worn-out oil pump and bushings. The repair kit of gaskets and seals is included in the common order for a complete reassembly of this transmission. Rare repair cases usually include replacement of the Direct package. In most cases friction friction components of this package are the first to get burnt because of high loads. Frequently, this transmission comes to the repair shop completely burnt friction elements. In such cases, specialists order a full kit of frictions as well as the kit of steel discs.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Isuzu	ELF	97-15	4 SP R/4WD	L4 3.1L 4.6L
Isuzu	TRUCK NPR	99-07	4 SP RWD	L4 4.75L 5.2L DIESEL
Mazda	TITAN	04-15	4 SP R/4WD	L4 3.1L
UD Trucks	CONDOR	97-14	4 SP R/4WD	L4 3.1L 4.6L

How to repair this transmission (Videos)

450-43LE Teardown

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout AW45043LE

AD4 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission AD-4, AD-8 is a French modification of the 01M (01P) unit. The AD-4 is intended for engines up to 2 liters and may be installed on FWD Laguna, Megan and Clio from Renault. The AD-8 modification was released a bit earlier for Safrane and Espace with 3 liter engines V6 produced in 1989-1998. Both transmissions are quite reliable and rarely met in repair services. Friction components for AD-4 are interchangeable with parts for the 01M.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		5,7	3,5-4	Dexron III

Technical issues and repair guidelines

Overhauls ofd this automatic transmission consist of the reassembly and cleaning of the transmission with replacement of seals and gaskets. Sometimes specialists replace friction componeand solenoids.

Specialists order the following for repair procedures:

- individual filter for AD-4 Megan

- individual filter for AD-4 Clio and Scenic

- filter AD-8

- repair kits of gaskets and seals, AD-4 frictions, which are interchangeable with parts for German transmission. Frictions for AD-8 are selected separately taking into account size and quantity:

- Kit of pistons AD4\AD8 consisting of 5 pieces.

This transmission is quite simple and repairable, after a proper repair it operates for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Renault	MEGANE	0	4 SP FWD	L4 1.6L

Instruction manuals and useful links

Link type	Source	Description
pdf	dogacelektronik.com	Fault finding AD4, AR4

A8LR1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 8-speed RWD automatic transmissions A8LR1, A8TR1 (4WD) with longitudinal positioning designed by Hyundai were installed on luxury cars with engines from V6 3.0 up to V8 5.0L since 2011. This transmission was launched in production in 2010 and after several years of testing on the Korean market, Hyundai engineers introduced some updates, which improved some hard parts and frictions. Some electrical mechanisms and computer settings were also changed.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	AT	RWD/AWD	500	9.6		ULTRA ATF SP-IV RR

Technical issues and repair guidelines

These transmissions rarely get in repair services, because of reliable rear drive construction which operates properly for the first 4-5 years of service without serious problems.

Ravenol SP-IV RR fluid is used for these finely adjusted transmissions. Specialists do not recommend using other types of fluid, because the oil in this transmission performs many other functions in addition to lubrication, cooling and hydraulic environment. Although the oil ageing slightly worsens its qualities, after running 80-100 thousand kilometers it is recommended to check it for transparency and change it together with the filter-pan, especially if the transmission operated at maximum loads.

One of the main soft spots causing problems in this transmission is the valve body with solenoids. This transmission is very sensitive to operation with contaminated oil under the condition of ultimate loads. Intensively operating VFS solenoids-electric-regulators are the first to reach the end of their lifespan.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	EQUUS	11-16	8 SP RWD	V6 3.0L 3.8L
Hyundai	GENESIS	11-16	8 SP R/4WD	V6 3.0L 3.3L 3.8L
Hyundai	GENESIS COUPE	11-16	8 SP RWD	L4 2.0L V6 3.8L
KIA	K9	12-16	8 SP RWD	V6 3.3L 3.8L
KIA	QUORIS	13-16	8 SP RWD	V6 3.3L 3.8L

How to repair this transmission (Videos)

Hyundai's new 8-Speed Automatic Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	drive.google.com	KIA A8LR1 Service information

9HP48 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

9 speed transverse ZF 9HP48 for the front drive was released in 2013 at two factories: in Saarbrücken for Europe and by Chrysler in Kokomo (USA) for Japanese and American cars - Honda and Chrysler. Both versions have significant differences in the range of spare parts and major components because Chrysler made plenty of changes in its version . It was tested on the American market and there were mostly problems with computer settings and electrics. ZF9HP48 is designed to transfer the torque from the engine up to 480 Nm, but as all transmissions with transverse positioning it is much less endurable to extreme stress and therefore it is installed on urban jeeps.9 gears are only required when the vehicle passes half a day at the 1st gear in urban traffic and when out of traffic it immediately gets on the freeway where the 9th gear serves to save fuel.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
9	AT	FWD	480	7.5	4	ZF Lifeguardfluid 9

Technical issues and repair guidelines

Rebuilding of a transmission is always made with a repair kit consisting of gaskets and seals (overhaul kit). In this case the filter is replaced as well .Prolonged driving with contaminated oil and worn-out sealing rings leads to rapid wear of solenoids, which operate evenly as a group and also a group fail around the same time period. But it actually requires a long time to have the solenoids fully unconditional.

ATF change is quite difficult and requires experience in automatic transmissions, especially with the 6-speed and 8-speed ZF automatics. Smell of burnt ATF or presence of metal grit of around 1mm is considered to be an indicator for a major overhaul of the automatic transmission even if the gearbox runs flawlessly.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Acura	MDX	14-16	9 SP 4WD	V6 3.0L 3.5L
Acura	RLX	16	9 SP FWD	V6 3.5L
Acura	TL	14-16	9 SP F/4WD	V6 3.5L
Chrysler	200	14-16	9 SP F/4WD	L4 2.4L V6 3.6L
Chrysler	TOWN & COUNTRY	16	9 SP FWD	V6 3.6L
Chrysler	TOWN & COUNTRY	16	9 SP FWD	L4 2.8L V6 3.6L
Dodge	DART	15-16	9 SP FWD	L4 1.4L 2.0L 2.4L
Dodge	PROMASTER CITY	14-16	9 SP FWD	L4 2.4L
Fiat	500X	14-16	9 SP 4WD	L4 1.4L 2.0L 2.4L
Honda	CIVIC	14-16	9 SP FWD	L3 1.2L L4 1.6L
Honda	CR-V	15-16	9 SP 4WD	L4 1.6L
Honda	ODYSSEY	16	9 SP FWD	V6 3.5L
Honda	PILOT	15-16	9 SP F/4WD	V6 3.5L
JEEP	CHEROKEE	13-16	9 SP F/4WD	L4 2.0L 2.4L V6 3.2L 3.6L
JEEP	RENEGADE	14-16	9 SP F/4WD	L4 1.4L 2.0L 2.4L
Land-Rover	DISCOVERY SPORT	14-16	9 SP 4WD	L4 2.0L 2.2L
Land-Rover	RANGE ROVER EVOQUE	13-16	9 SP F/4WD	L4 2.0L 2.2L

How to repair this transmission (Videos)

9HP 9-speed transmission

9HP Transaxle Operation - Part 1 of 2

9HP Transaxle Operation - Part 2 of 2

ZF 9HP48 and Chrysler 948TE

Instruction manuals and useful links

Link type	Source	Description
pdf	Atra	Introduction 9HP48/948TE
web	Wikipedia	ZF 9HP transmission
web	gearsmagazine.com	Chrysler’s 948TE
pdf	fzth.de	Scheme 948TE

8L90 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The RWD automatic transmissions with longitudinal positioning Hydra-Matic 8L90 (M5U) and 8L45 (M5N, M5T) were designed in 2015 for Cadillac CT6 with new engines (3.6 liters) and also suitable for 6-liter engines V8. The design of this modern transmission is similar to 8HP by ZF and has a lot of same "features", like Start-Stop system on at traffic lights, used to save more fuel.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	AT	RWD/AWD	1000	11,7	6	Dexron HP

Technical issues and repair guidelines

The transmissions has much higher reserve on components than its German competitor and should operate at least 200-300 thousand kilometers before the first overhaul ( under the condition of well-timed ATF change). In case of frequent “kickdown” usage with a switch-on of controlled slipping of the lock-up clutch, the wear-out of friction elements occurs quite rapidly and contaminates the valve body, fluid and filter. The filter is made of plastic with a two-layer felt membrane and its better to change this part in a timely manner.

The oil and filter should be changed when there are any suspicions related to oil transparency. Such situations may occur after travelling 40 thousand kilometers or 80 thousand kilometers depending on driving style and adherance to the transmission warm-up rule before driving in winter time. Removal of the pan allow specialists to estimate the level of components wear-out and valve body contamination.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Cadillac	ATS	15-16	8 SP RWD	V6 3.6L
Cadillac	CT6	15-16	8 SP 4WD	V6 3.0L
Cadillac	CTS	15-16	8 SP RWD	V8 6.2L
Cadillac	ESCALADE	15-16	8 SP R/4WD	V8 6.2L
Cadillac	ESCALADE ESV	15-16	8 SP R/4WD	V8 6.2L
Chevrolet/GM	CAMARO	15-16	8 SP RWD	V8 6.2L
Chevrolet/GM	CORVETTE	14-16	8 SP RWD	V8 6.2L
Chevrolet/GM	SIERRA	14-16	8 SP R/4WD	V8 6.2L
Chevrolet/GM	SILVERADO	14-16	8 SP R/4WD	V8 5.3L 6.2L
Chevrolet/GM	YUKON XL	06-16	8 SP R/4WD	V8 6.0L 6.2L

How to repair this transmission (Videos)

TransTec 8L45 Teardown

Valve Body Disassembly

8L90 Case Disassembly

8L90 assembly

Instruction manuals and useful links

Link type	Source	Description
pdf	Atra	Introduction 8L90
web	gmauthority.com	Specification 8L90
web	sandyblogs.com	Harsh Shifting on the 8L90
web	sandyblogs.com	Reprogramming Procedures for the 8L90
web	sandyblogs.com	All-New 8L90 8-Speed info

9T50 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 9-speed automatic transmission Hydra-Matic 9T50 for front-wheel drive vehicles was designed by GM and was officially showcased in December 2016. This transmission was intended to replace its 6-speed predecessor. According to GM engineers, the 9T50 transmission allows striking a balance between high dynamic parameters and fuel economy. The size of this transmission is the same as the size of its 6-speed predecessor, but the Hydra-Matic 9T50 also supports start/stop technology and has a new torque converter.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
9	AT	FWD/AWD	380	10	6,3	Dexron HP

One of the peculiarities of this transmission is a selective clutch, which may disconnect the transmission from the engine and operate in the rundown mode. The first car to operate with this transmission was Chevrolet Malibu. The first gear of the 9T50 transmission is very short (gear ratio is 4.69), so the car can move very smoothly from a standstill. The 9-th gear is designed for economical and more relaxed driving (gear ratio is 0,62).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	EXCELLE GT	15-16	9 SP FWD	L4 2.0L
Buick	LACROSSE	16	9 SP F/4WD	V6 3.6L

Instruction manuals and useful links

Link type	Source	Description
pdf	sandyblogs.com	TechLink 9T50

7DCL750 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 7DCL750 7-speed dual-clutch transmission was designed by Getrag for transaxle and mid-engine positioning in sports vehicles with RWD or AWD.

The 7DCL750 has an optimal installation length, which became possible thanks to a 4-shaft structure. The ratio of 1-st gear, 7-th gear and final drive can be defined and adopted to the respective usage. This transmission also may have a mechanically or electronically-operated differential locking device. The dry-sump lubrication system helps to enhance the level of efficiency and fuel consumption. In addition, this system also helps to keep to minimum windage losses

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DCT	RWD	750	7,8	3,5	DCTF105786

Typical problems:

Mechanical friction suspension from hot ATF clogs valves of the valve body and solenoids, then it appears on friction surfaces and contributes to wear, vibrations and sticking of valves, especially when the friction layer is worn down to the glue basis. It leads to the chain reaction of metal wear and further contamination of ATF. Thus, DSG transmissions are equipped with outside filters of high capacity. Getrag engineers recommend changing this filter more often, especially if the transmission is old.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ferrari	CALIFORNIA	08-16	7 SP RWD	V8 4.3L
Ferrari	F12	12-16	7 SP RWD	V12 6.3L
Ferrari	F458	09-15	7 SP RWD	V8 4.5L
Ferrari	F488	15-16	7 SP RWD	V8 3.9L
Ferrari	F599 GTB	09-11	7 SP R/4WD	V12 6.0L
Ferrari	F612	10-11	7 SP R/4WD	V12 5.7L
Ferrari	FF	11-16	7 SP 4WD	V12 6.3L
Ferrari	LAFERRARI	13-15	7 SP RWD	V12 6.3L
Ford	GT	16	7 SP RWD	V6 3.5L
Mercedes-Benz	GT	14-16	7 SP RWD	V8 4.0L
Mercedes-Benz	SLS	10-14	7 SP RWD	V8 6.3L

How to repair this transmission (Videos)

Ferrari 458 Getrag Double Clutch Transmission Fix

Instruction manuals and useful links

Link type	Source	Description
pdf	getrag.com	Press information 7DCL750
pdf	getrag.com	Technical data 7DCL750

7DCT300 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 7-speed automatic transmission PowerShift 7DCT300 was manufactured by Getrag. This transmission with 2 clutches is intended for front-wheel drive cars with the engine east-west mounting. The design of this transmission successfully combines two multiple-disc clutches and electro-hydraulic gearbox actuators. The 7DCT300 is designed on the basis of the 6-speed PowerShift 6DCT250. The basic design of the transmission is implemented according to the three shaft configuration. At the same time the total weight of the transmission was reduced from 72 to 67kg. The development of the improved design was made because of more severe requirements for fuel economy, dynamics and environmental compatibility of cars.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	DCT	RWD		2,1	1,8	DCTF105786

Designed on a modular platform, the 7DCT300 transmission is intended for engines with the torque capacity up to 300 Nm. Engineers of this transmission solution think that the most remarkable feature of this transmission is an intelligent power transmission system Smart Actuation. This system facilitated to reducing the powertrain power consumption to 40 volt and made this transmission more efficient. Electric actuators, as a part of the transmission control mechanisms, can operate with the non-running engine and when the car is not moving. The electronic transmission control unit (TCU) is mounted on the transmission case. By means of the wiring harness, the TCU is connected to 5 electric motors, 2 speed sensors, oil temperature sensors, sensor of engaged gear and two pressure sensors in clutch actuators. The TCU software was designed taking into account demands of 23 automakers using Getrag transmissions with 2 clutches. Usually, the transmission is equipped with the open-type differential, so the oil filling operation is performed when the transmission is installed on the car and when the wheel drives are mounted. However, at the request of the car manufacturer, the PowerShift 7DCT300 may be equipped the differential of the closed type. Currently, dual-clutch transmissions produced by Getrag are installed on such cars as Ford Focus, Ford Galaxy, Renault Clio RS, Honda-Acura, Ferrari 458 Speciale, BMW-M, Volvo, Qoros.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	ECOSPORT	16	7 SP FWD	L3 1.5L

How to repair this transmission (Videos)

GETRAG 7DCT300

Instruction manuals and useful links

Link type	Source	Description
pdf	getrag.com	7DCT300 general information
video	getrag.com	7DCT300 Product animation

6L45 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The Hydra-Matic range 6L45 - ... 6L90 is the second generation of modular-type 6-speed automatic transmissions, used for RWD vehicles. The 6L80 and 6L90 were the first automatic gearboxes of the Heavy-duty class designed in 2005. Next year 6L50 \6L45 gearboxes of the Medium-Duty class (with a lower torque) up to 450 Nm replaced BMW gearbox, which was popular in repair services. The 6L45E (GA6L45R) is a constructively modified 5L40 (which was actually replaced by the 6L45E in 2007 ). Mainly used with budgetary BMW-3 and X3 with engines 2.5l - 3.0L. 6L50, 6L80 and 6L90 transmissions may be considered as quite reliable RWD 6-speed gearboxes of GM series. European modifications 6L45 /R have been used since 2006 on BMW Х1, Х3 of 1-st 3-rd and 5-th series and manufactured in Strasbourg, France. These gearboxes mainly differ in electrical components.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD	450	9,8	6,2	Mercon SP

These gearboxes usually get in repair services for scheduled ATF change, replacement of the filters with the pan gasket. ATF gets contaminated because of aggressive accelerations and wear-out of the lock-up clutch. It is recommended to change ATF in accordance with its contamination level, but no later than after travelling 80 thousand kilometers.

Typical problems

The problem detected on the 6L80 (manufactured before 2008) is related to the design of the pump cover and cranking of filler rings resulting in problems with shifting from the 2-nd to the 3-rd gear and delays in switch-on of Forward or Reverse gears.

In case of the overhaul, it is recommended to check the leak integrity of the drum 555. There may be some hidden cracks leading to the operation pressure losses in packs causing problems when shifting gears 2-3 and Reverse. Overheating is dangerous for all pistons, which have to be fully replaced. It is the problem inherited from its 5-speed predecessor 5L40E.

All pistons and retainers are replaced quite frequently (kit of pistons 6L45-50). Problems with the torque converter (TC) may also occur in these gearboxes. The wheel-hub early gets out of order. Rare and complicated cases of the overhaul show some vulnerability of the pack (4-5-6 Clutch), which in neglected cases leads to burning of all frictions, including steel discs and pistons. The reason is often related to wear-out of the TC bushing and TC itself.

The torque converter is often considered to be a soft spot in American gearboxes. After 100-150 thousand kilometers (depending on engine and driving style), it is recommended to test the TC seal for leaks. When there are leakages in the seal or ATF gets rapidly contaminated, then it is desirable to get TC in repair services to prevent problems with the pump or the valve body. This measure particularly should be applied when automatic gearboxes operate jointly with motors (with maximum torques).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
BMW	5-SERIES	06-10	6 SP R/4WD	L6 2.5L 3.0L
BMW	6 SERIES	07-13	6 SP RWD	L6 3.0L
BMW	Z4 ROADSTER	09-11	6 SP R/4WD	L6 3.0L

How to repair this transmission (Videos)

Disassembly

Manual Valve

6L90, building the tehcm pressure switches

6L80-E Transmission Repair

6L80E Teardown Inspection

6L80E Valvebody

GM 6L80 E Transmission - No Forward

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 6L45
pdf	Sonnax	Valve Body Layout GM 6L45, 6L50, 6L80, 6L90
pdf	Sonnax	Vacuum test 6L45, 6L50, 6L80, 6L90
web	Sonnax	6L80 Family Identification Guide
web	Sonnax	Location and Function of New #8 Checkball for 6L80/90
web	Sonnax	6L80/6L90 "No Movement" After Repair
video	Sonnax	6L80 Series Transmission Upgrades & Repairs

6DCT250 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6DCT250 6-speed transmission has been developed for front-transverse installation in medium and compact cars with the torque capacity up to 280 Nm. This transmission is equipped with a dual wet clutch. Currently, this transmission is installed in almost all Ford models.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DCT	FWD		1,8	1,8	75w90

A smooth gear shifting is ensured thanks to the parallel operation of two main shafts, actuated by the clutch system. In practice, it is implemented in the following way: one clutch selects the necessary gear, while the other one prepares the next gear for engagement. It is worth mentioning that the gear shifting process in the 6DCT250 transmission rules out the possibility of torque losses. In other words, the automatic transmission successfully combines all conveniences of automatic transmissions and the efficiency of manual transmissions. This transmission may have a separate PTU with AWD system, as well as a start-/stop feature without modification of the hardware. Combined with an E-motor, the gearbox may also be applied in a hybrid drive.

Peculiarities of operation:

In terms of design, this transmission is a nonstandard solution, which specifies special requirements for the maintenance and operation of the vehicle:

- When stopping the car, the driver has to press the brake pedal, using the handbrake lever, and only then shit to “P” parking position;

- When using the vehicle in the "Select-Shift" mode, the driver should not keep the button “+/-“ pressed;

-When the engine runs idly, the driver should switch the selector into “P” (parking) or into “N” (neutral) mode;

- When selecting “R” (reverse), “S” (sport), or “D” (drive) mode, it is not recommended to keep the brakes engaged for a long time;

- Transmission repair specialists recommend changing of ATF and filter after each 45 thousand kilometers. It is important that this procedure should be performed at special services.

Problems

The most common faults in the 6DCT250 Powershift transmission are related to the clutch system. Due to structural stiffness, this transmission component responds to ECU malfunctions, which may lead to wedging and gear failure. In some cases specialists detect ATF leakages in the primary shaft seal. The ATF appearance on the clutch may lead to slippage.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	B-MAX	12-16	6 SP FWD	L4 1.5L 1.6L
Ford	C-MAX	14-16	6 SP FWD	L4 1.5L
Ford	FIESTA	10-16	6 SP FWD	L3 1.0L L4 1.2L 1.5L 1.6L
Ford	FOCUS	11-16	6 SP FWD	L3 1.5L L4 1.5L 1.6L 2.0L
Ford	TRANSIT COURIER	15-16	6 SP FWD	L4 1.6L

How to repair this transmission (Videos)

Ford Dual Clutch Transaxle (DCT) DPS6

DPS6 Transmission Teardown

DPS6 Internal Operation

Slipping/Shudder Clutch replacement

Dual Clutch Transmission Clutch Assembly Removal and Installation Guide

Instruction manuals and useful links

Link type	Source	Description
pdf	www.getrag.com	Specifications 6DCT250
pdf	getrag.com	Press information 6DCT250
pdf	automaticchoice	Scheme 6DCT250

4L85E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission 4L85E was firstly presented in 2001 together with powerful engines Duramax V8 (with torque reaching up to 650 Nm). This transmission was installed only on large SUVs, pickups and minibuses. This transmission is very powerful and can be applied cars which take part in off-road racing, drag racing or custom street driving.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/4WD	650	13,6		Dexron VI

These transmissions have issues with early style 12 pin harnesses in which transmission fluid leaks around the harness and shorts the pinouts causing transmission to go into "limp mode" (some manuals say "limp home mode"). This issue can be easily rectified by simply cleaning the plug

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	VAN FULL SIZE 3500	95-09	4 SP RWD	V6 4.3L V8 4.8L 5.7L 6.0L 7.4L 8.1L 6.5L 6.6L DIESEL

4L40E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 4L40E produced by GM found application on the most common BMW 318 (since 1998). This automatic transmission was designed on the constructive basis of a reliable 4L60E, but were produced in Europe for the Bavarian automobile factory. This range of automatic transmissions replaced the 4-speed 4L30E and had been in production until 2007, when GM replaced these transmissions with the 6-speed 6L45. In terms of design the 4L40E (5L40) is the most simple, robust and reasonably priced transmission.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	360	9	5,5-6	Dexron VI

Technical issues and repair guidelines

The repair of this transmission mainly lies in the replacement of filter, gaskets and seals (preventing oil leakage), and replacement of burnt friction elements. All parts are interchangeable with 5L40E and 5L50E. Frictions are one-sided as in the popular DP0 transmission. The pack (Direct Clutch; 2nd Coast) burns twice as frequently as other clutch packs.Generally, this gearbox is considered to be reliable and almost “invincible”, when avoiding heavy ATF contamination by friction dust and the abradant which wears out not only friction nodes, but also the valve body.

This issue (oil contamination) often results in self-regulating pump becoming “unregulated”, also remaining in the mode of ultimate capacity. It leads to the rapid gear-shifting as well as to increased pressure in packages resulting in pistons damage. Issues with pistons is a typical soft spot for the 5-speed 5L40E and 5L50E (BMW Х5). The rubber-covered piston (forward) most commonly gets out of order because of its design peculiarities.It is usually recommended to take care about the ATF quality for this transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
BMW	3-SERIES	00-05	4 SP RWD	L4 1.9L L6 2.0L 2.8L

How to repair this transmission (Videos)

Part 1 Transmission Service

Part 2 Transmission Service

Instruction manuals and useful links

Link type	Source	Description
pdf	shinseiauto.com	Scheme 4L40E

2ML70 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 2ML70 gearbox is a 4-speed rear drive which can be configured in a two or four wheel drive application. The secret of this transmission lies in combination of 2 electric motors inside the transmission, which serve not only for driving the car under certain conditions, but also for starting the engine. The 2ML70 transmission has several important advantages when compared to its gasoline counterparts: reduced fuel consumption, improved performance characteristics, reduced amount of toxic emissions.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	Hybrid System	RWD	515	12.3	10.8	Dexron VI

This transmission doesn’t have a torque converter. It is equipped with stop/start technology and therefore has a 12 volt auxiliary pump to keep the 1-2 clutch primed any time the engine shuts down. The design of 2ML70 also includes 3 planetary gear sets, 2 rotating clutch packs and 2 fixed clutch packs. The gearbox functioning is controlled by a Transmission Control Module (TCM) which is located inside the transmission and the hybrid systems operation is controlled by the Hybrid Control Processor (HCP) located under the hood.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
BMW	X6	09-14	EVT 4WD	V8 4.4L
Cadillac	ESCALADE HYBRID	07-13	EVT R/4WD	V8 6.0L
Chevrolet/GM	SILVERADO HYBRID/SIERRA HYBRID	09-13	CVT R/4WD	V8 6.0L
Chevrolet/GM	TAHOE HYBRID	07-13	CVT R/4WD	V8 6.0L
Chevrolet/GM	YUKON HYBRID	08-13	EVT R/4WD	V8 6.0L
Chrysler	ASPEN HYBRID	9	CVT R/4WD	V8 5.7L HEMI
Dodge	DURANGO HYBRID	9	EVT R/4WD	V8 5.7L HEMI
Mercedes-Benz	R CLASS	09-11	CVT R/4WD	V6 3.5L

How to repair this transmission (Videos)

GM Two Mode Hybrid

What is a two-mode hybrid?

Instruction manuals and useful links

Link type	Source	Description
web	www.searchautoparts.com	AN INTRODUCTION TO GM'S 2ML70 TWO MODE HYBRID TRANSMISSION
pdf	www.atraonline.com	2ML70 (RPO M99)

10R80 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 10R80 is a 10-speed automatic gearbox designed thanks to fruitful cooperation between Ford and GM (10L90). Both companies pointed out the fact that while the mechanical part of the gearbox was developed collaboratively, the software part of the 10R80 will be different for each manufacturer and, as a result, their corresponding powertrain structures should not necessarily resemble each other in view of gear shifting algorithms. This transmission has 10 forward gears, three of which are overdrive ratios. It's deep 4.69 to 1 first gear ratio is the lowest in its class and it features a relatively tall 0.63 to 1 final overdrive ratio.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
10	AT	RWD/4WD	800	12.9	8	Motorcraft ULV

A built-in electrohydraulic pump ensures that the "start-stop" feature operates with minimal delay. The 10R80 includes 3 operation modes - "Tow Haul", "Sport", and "Normal", with each mode changing the gear shifting algorithm and characteristics to compliment particular forms of driving behavior. Since the gearbox has 10 forward gears, its running characteristics and, more importantly, fuel efficiency is maximized by the transmission's capacity to get a suitable ratio for current operating conditions, such as engine speed, load, and car speed. This transmission became a standard option for the 2017 F-150 equipped with the 3.5L Eco-Boost engine.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	F-150	16	10 SP R/4WD	V6 3.5L V8 5.0L
Ford	F-150 SUPERCREW	16	10 SP R/4WD	V8 5.0L
Ford	MUSTANG	16	10 SP RWD	L4 2.3L V8 5.0L

How to repair this transmission (Videos)

10-speed Transmission Assembly

Instruction manuals and useful links

Link type	Source	Description
web	www.f150hub.com	0R80 10 SPEED AUTOMATIC TRANSMISSION RATIOS

3HP22 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

3-speed automatic transmission 3HP22 was produced by ZF company in 1973. This transmission was intended for rear drive passenger vehicles with motors M10, M20, M30 of BMW product range (big coupes and sedans, 3, 5, 6 and 7 series). This automatic transmission transmits the torque up to 320 Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD	320	2.4	2	Dexron II

Technical issues and repair guidelines

One of the most common sources of problems in this 3HP22 transmission is the governor. The governor is a shifting pressure regulator on the output shaft of the transmission. The gear shifting point according to the car speed depends on the above mentioned governor.The wear-out of niches for plastic rings on the hub of the last transmission clutch is considered to be another soft spot. This problem also may lead to the governor pressure loss.

How to repair this transmission (Videos)

3HP22 valve body rebuild

Instruction manuals and useful links

Link type	Source	Description
web	wikipedia	ZF 3HP22 transmission

Transmission Leak Test Unit Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Leak test units allow checking circuit integrity for transmission units through use of hydraulic pressure. These tools guarantee time saving since modern models do not require removal of the transmissions off vehicles. It is a universal machine which merely requires appropriate leak test plate to fit any automatic gearbox. The 4L60 transmission, 4L80 transmission, ZF transmissions are some of the most demanded for this transmission service.

The answer to the question on the reason of oil flowing out of the transmission troubles many transmission specialists. Transmissions oil leakage is in the group of problems with which almost every driver ever found. Under the car there are oil stains that are gradually increased. Set of lubricants is considered to be an important part of the vehicle. Such a problem leads to major failures. Friction of the contacting parts goes uncontrolled, wear debris is stopped from leaving the drivetrain, the assembly doesn’t cool down. It is unsafe and could cause fire.

Various leaks at the junction of gearbox and engine most likely can occur due to the following reasons: wear-out or failure of seals, various defects in shafts and seals, emergence and increase of clearance in the shafts (input shaft, etc.), sealing compound fails to provide the desired sealing, loosening of clamp holdings, failure of properties of seals and gaskets and other effects.

Transmission Dyno Stand Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Dyno stands allow testing complete gearboxes in assembly checking their performance and understand if it is comparable to benchmark characteristics. It is the tool that is certainly needed to provide certified transmission quality. There are options that allow advanced testing of FWD, RWD, AWD automatic transmission vehicles, for both civil and heavy duty models. A dyno stand used to be an expensive option for big-scale car transmission rebuilders but more accessible quality options start to emerge on the international transmission service market.

Why is it important to use a transmission dyno test stand?

What are key components of a transmission dyno?

What is the difference between electric motor and combustion engine dynos?

Principle of operation | What types of load cells are there in the dynos?

History of transmission dynos on the industry market

Pressure gauges in transmission dynos

Importance of hardware with transmission dyno stands

Importance of software with transmission dyno stands

Major suppliers of automatic transmission dynos

The transmission of an essential part of a vehicle drivetrain system, transferring power to the wheels, doing gear switching, distributing load. Depending on the context, to a large degree term ‘transmission’ is synonymous to ‘gearbox’.

What is the utility of using transmission dyno test equipment?

In the transmission repair industry, testing of a complete automatic transmission unit is imperative for large remanufacturing companies dealing with large repair volumes, is quite desirable for medium-scale companies working widely on the national level and supplying to other countries, and is a dream for smaller transmission shops that always do test-on-the-car checks to verify the repair procedure. In addition, many educational institutions (like tech colleges) need dynos for proper students’ skill-learning process. Production companies use transmission dynos in their EOL tests (end-of-line testing).

“Dynamometer” consists of two words - dynamo (Greek for “power in motion”) and meter (also Greek for “measurement”). Very often, it is simply called as “dyno”. A dyno stand used to be a costly tool solely for big-scale transmission rebuild shops, nowadays, however, more accessible options of these tools are emerging on the international transmission service market.

One who is new to transmission repairs may actually wonder: ‘Why a transmission should be dyno tested?’ It is primarily about warranties and guarantees given by the provider of repair services. A dyno test ensures that a transmission is performing well and adequately under certain conditions of operation and this gives a huge grade of certainty that the transmission will last full life expectancy.

The dyno testing means that you mount a transmission in the dyno test rig and drive it through various paces. The idea of such testing is simulation of real-life operation conditions as if it were driven in the car on the road. At this, the gearbox is taken through a complete set of operations, with gear and speed switching, and in each gear operation is performed through the design speed range. Certainly, it is vital to capture output values, and these are monitored in the test process.

Reputable transmission remanufacturers set their goal to return the rebuilt product to original factory specifications. With dyno testing, the following key parameters are checked: torque, temperature, pressure. Also, operations efficiency is checked and sensor functionality test is performed. The tech operator is able to verify bolt torque and presence or absence of leaks in the system. To put it straight, the dyno test assures that your gearbox operates according to the factory specifications with due regard to design speed and range of gears.

You need to dyno test gearboxes when:You strive to provide top quality of your rebuilds.

You want to be sure of the longevity of warranties that you give.
You want to speed up your repair processes.
Your partners who contract you in large volumes need assurance of compliance with highest reman standards.
You value your shop’s reputation and you want to avoid unwanted returns damaging

Basically, without dyno testing you have difficulty proving that the gearbox will not fail in operation conditions. Although the guarantee might have a fault covered, it is your reputation that you need to protect and avoid frustration when a gearbox is returned back with faults.

What is more, health of the transmission means that no harm will be done to the drivetrain and no further damage to the engine. Another vital idea is that a high quality reman transmission can be better performing than a new factory one. This is important for transmission performance shops and racing car workshops.

What are key components of a transmission dyno?

It is important to understand key components of a dyno test rig as a transmission specialist may wonder how it functions.

Primarily, modern dynos are fully digital and allow for highly accurate easy-to-perform repeatable automotive transmission testing. The important factor here is software and hardware, which is realized in the controller system. These dynos simulating automotive load conditions are typically quite universal and adaptable to various modes of wheel drive and automatic transmission types (including CVT transmissions). In order to cover this universality the test rig is performed with due regard to capacity requirements, motor horsepower specs, number of load cells. Let us cover the components of the body of a transmission dyno.

High-output motor (nowadays it would be an electric motor)
Load unit (for dynamic loaded testing). At this, number of load cells is varied for various applications: 1 unit – for RWD (rear-wheel drive) vehicles, 2 units – for FWD (forward-wheel drive) vehicles, 3 units – for AWD (all-wheel drive) vehicles
Jib crane for transmission mounting and dismounting
Pumps with hoses to fill and drain transmission fluid
Pressure sensors
Oil tank and drip trays
Stall brake
Quick release hose fittings

Additionally:

Electric shuttle motors allowing positioning for different transmission configurations
Tooling kits for transmission positioning avoiding any potential harm to pumps or certain transmission components
Bushings for precise transmission alignment

What is the difference between electric motor and combustion engine dynos?

Modern dynos run on electric motors, they use electricity stored in batteries and power electromagnets driving axles.

Combustion engines run on gasoline, which explodes in an enclosed space – it is a well-known process happening in most of the cars driving on our roads, hence the name. In vehicles, this combustion moves pistons, which rotate engine’s crankshaft and all that controls rotation of the vehicle’s axle. This solution is pretty much obsolete and not used in up-to-date dynos for a number of reasons:

CE has many more parts and occupies more space (CE with ~2000 parts and EM with ~20 parts). Fewer parts also means easier serviceability and maintenance.
Disposable fuel with electric motors, while in a combustion engine, the disposable fuel is gasoline, which must be carefully stored, as there is a danger of ignition. What is more, fuel leftovers must be exhausted out of the after combustion.
Electric motor battery packs are expensive but gradually become more accessible.
With electric motors little energy is wasted, but with combustion engines quite a serious percentage of energy is lost along the way. Therefore, it’s the gas-powered vehicle that needs more energy.
It is more comfortable and convenient to service an electric motor in a transmission shop surrounding, if comparing to a combustion engine.

Overall, 75kw (or ~100 horse power) is enough to drive modern transmission dynos for light-duty and medium-duty application. At that, electric motors are very much preferred.

Principle of operation

It is important to distinguish transmission test stands from these two types of dyno stands: engine dynamometers and chassis dynamometers. With engine dynos, the engine is removed from the vehicle and installed on the stand by connecting directly to the flywheel. For this purpose, transmission specialists use special adapters and it is also necessary to connect the cooling system, as well as some other components - this procedure takes a lot of time. Engine developers and manufacturers mainly use these stands.

Chassis dynos allow for testing of the vehicle as it is driving on the road, fully assembled. These are rather popular among people doing racing cars or performance vehicles.

Transmission testing stands are suitable for both transmission manufacturers and transmission repair service shops. During testing of complete gearboxes their performance is compared against benchmark characteristics. Multiple readings are taken using corresponding sensors and transducers, their readings are converted to visually explicit and perceivable information. Obviously, transmission dynos vary in their design to cover FWD, RWD, AWD automatic transmission vehicles, support and fit civil light-duty and/or heavy-duty models. Precision alignment tooling and data acquisition & control systems play an important part in quality transmission testing.

What types of load cells are there in the dynos?

Dynamometers are classified by the method of creating a load. Nowadays, the accepted brake standard in a transmission dyno is eddy current brakes.

EC brake is an electrically controlled brake with air cooling. In it, load is created by inducing a magnetic field in a rotating disc. Heat produced by the rotating disc is dissipated in air. Moving parts are stopped by EC brakes with the help of drag force. These brakes are a great option for lower power applications and dynos up to 250 hp.

Water brake works on the transfer of water momentum creating load on the tested unit with the absorbed power heating water. Usually, these consist of a turbine / propeller, which is mounted in an enclosure with water. Water brake are for high power applications far over 250 hp. Largely, for engine dynos with thousands of hp.

Alternating current dynamometers are another option which is less frequent when compared against EC’s. These are used for engine dynos and the idea is in mimicking the load placed on the engine as it powers vehicle.

History of such equipment on the industry market

Transmission testing equipment has a particular history in the USA, the leader of car industry. The world’s largest manufacturer for this type of equipment – PowerTest – is located in Wisconsin. They started in 1976 and grew to acquire a large number of brands and companies from the industry. Nowadays, PowerTest owns such brands as AIDCO, Axiline, Hicklin – all of them shall be known to people who spent decades in the transmission industry.

Another well-known US manufacturer is MAE (Mustang Advanced Engineering) who were on the market since 1970’s as well. As of today, they provide a system for testing automatic passenger car and light truck inline and transverse transmissions as well as systems for medium- and heavy-duty applications.

There are some other companies located in the USA but they are far less active and less known to a global audience, as of today.

Although, dynamometers have been around since as far as the 18 ^th century, quality transmission dyno options are not as many as one might have thought.

In the 21^st century, USA are not sole prominent manufacturers and they need to compete with companies like RayTech from China or Hydra-Test from the UK for the global buying audience.

Pressure gauges in transmission dynos

In previous decades, the equipment output gauges were analog but nowadays there is obvious tendency for digitalization. With modern control systems, the process of running through gears and checking electronic solenoids is automated. One single system runs many different vehicle and transmission types.

If a transmission stops working because of a sensor, harness, connector or solenoid, it will be visually shown on the screen, explicitly as to identify this failure. Comprehensive data on each sensor can be compared against the benchmark result and thus it will be easy to determine whether that particular sensor is good or bad.

Multiple fluid pressure gauges enable thorough shift timing evaluation and adjustment. Controller box ordinarily comes for 8 pressure sensors with quick fit connectors. This can be expanded to 2x times (total 16 pressure sensors) if this happens to be required in the technological process. Readout in modern dynos is easy to adjust for any needs – especially if the software is appropriate for client-specific demands.

Importance of hardware with transmission dyno stands

Modern advanced dyno stands allow control and full testing of electronically shifted Mechatronic gearboxes and valve bodies. The importance of hardware for such dynos cannot be understated.

Modern dyno stands provide complete computerized control and with that extremely precise test procedures are easy to repeat. Some companies like Axiline concentrate on the US domestic market. However, the range of supported gearboxes is typically large: the dynos fit most USA home and non-national RWD, FWD, transverse, and Continuously-Variable Transmission gearboxes. These dyno stands check:

gearbox line pressure,
TC lockup and downshift,
shift point and response,
stall speed, and more.

At this, emulated load conditions for vehicles are applied and speed and load are measured with potentiometers. Transmission rebuilders will be able to confidently spot ATF and pressure leakages, check controls of the systems and hydraulics, and perform minor corrections with the gearbox still being mounted on the tester.

Reliability of hardware and flexibility of software are equally important for efficient use of transmission dynos.

Hardware is the brain of a transmission test stand. You do not have to be an IT-specialist to know to value enduring components that will serve to last for years and that will be protected from any electric malfunction.

In many cases, a physical body of the transmission dyno is still able to last for years, however, the hardware or the controller itself is very obsolete and cannot meet demands of those new development that have come by recently. When looking for such an advanced tool, it is also vital to look into this aspect of the equipment – how is it going to be supported after a couple of years of operation.

For instance, the most-professionally done Chinese dynos are looking really good, but the hardware part here is just a contribution and doesn’t bear any advantages. Axiline (at PowerTest) has quit updates for their controller system and just go with what had been on for many years now.

A good option to look into are companies that supply controller systems separately form the dyno testers. This means that they are concerned about all the aspects of the equipment: physical, hardware, software – and can deliver a lasting product. Hydra-Test’s HTC-S is adaptable for existing dynos from former years. If the machine has served years and is still functioning well, it can be easily refitted with a new controller box – enhancing the functions and data validation and processing.

For instance, among transmission dyno users from the USA and Europe there is often a situation when their current system is obsolete and shows the following deficiencies:

Difficult process of programming new units.
Inability to smoothly ramps solenoid current.
No support for newer developments that came into market after 2020.
Absence of reliable tech support from the manufacturer.
Current transmission controller being no longer in production.

A new controller generation tackles these issues quite successfully and relatively easy. If you happen to be negotiating with a particular company’s manager, ask all of those questions upfront. New controller systems ideally have to come in a modular format when it is possible to build up a controller from several modules facilitating the support and any future upgrades.

New units coming to the market can be controlled efficiently with adaptability and flexibility of software. Ask your supplier if it is possible to write your own test scripts, this feature may be hidden but is pivotal for efficient use of transmission dynos.

Interpolation feature allows for solenoid ramp up, and with ease. New developments like Mercedes 722.6 or latest Chrysler models (like 68RFE) are supported equally with older designs.

Technical support is pivotal here. You do not want to be stuck with a fault that your supplier cannot be resolved for you. Large transmission equipment companies or companies coming from non-European countries oftentimes have these issues.

As an important note, remember that mechatronics have a different testing method and a 3 ^rd party supplier of equipment cannot have OEM access codes. Their use is restricted and protected. Therefore, do not expect that your transmissions can be tested along with their mechatronics components. It is simply not the case.

Mechatronics are excluded from the testing circuit with universal transmission dynos. They are tested separately by individual OEM tools – like ZF Testman and the like for other OEM’s. Double- or triple-check it if your potential supplier promises to supply mechatronics testing with their equipment.

Importance of software with transmission dyno stands

The IT field is on the rise and its advancements have also concerned the pretty much conservative transmission repair industry. When considering a transmission dyno, check for the following factors:

Date of software release
Frequency of software updates
Ease of update installations
Presence of online tech support
Possibility of desk sharing sessions (for example, via TeamViewer)
Flexibility of operational algorithms and their adjustments to clients’ needs
Convenience of output data readout and printing out
Attractive and user-friendly design

In fact, the software factor oftentimes goes without notice but it plays an essential role in efficacy of the dyno system. Just imagine running your high tech tool on Windows XP when it is 2020’s. This discriminates the whole investment.

Major suppliers

Nowadays, it is easy to commerce internationally and the suppliers are not limited to their local markets. US companies supply to Europe and to Turkey, Chinese suppliers have clients in the Middle and Near East. European suppliers have clients all across the globe – from Mexico to New Zealand. A certain group of suppliers works chiefly for the post-USSR countries.

1. Power Test

Active since: 1970s

Location: Wisconsin, USA

Types of equipment supplied: transmission dyno test stands, engine dynos, chassis dynos, valve body test stands, torque converter repair equipment, and other (all via different brands – Axiline, AIDCO, TCRS)

About: on the market for over 40 years, Power-Test has been providing test equipment to both manufacturers and rebuilding facilities and distributors in various field of industry. These include mining, oil & gas, power generation, and particularly military applications, marine, and construction.

Product updates: not recently.

Power Test has been acquiring local USA companies under one hood and is the largest company producing these types of products in the world. At that, the most powerful products are by AIDCO as they are for military applications. Test stands for transmission shops come as contributing to overall Power-Test profile.

CHECK OUT PRODUCTS https://go4trans.com/superflow-dynamometers-and-fl...

2. RayTech (Guangzhou Ray Technology Solutions)

Active since: 2010s

Location: Guangzhou, China

Types of equipment supplied: transmission dyno test stands, valve body test stands, torque converter repair equipment, and transmission parts.

About: Some Chinese suppliers cannot be counted on, simply because of how they present their product. RayTech is different in these terms although their web presence is also a little unclear to a European or American potential buyer. They also take part in certain expos across the globe.

Product updates: new test plates for RayTech equipment.

Raytech is probably a most recognizable supplier of transmission equipment (along with a Chinese company TranSpeed). Despite having a good portfolio and attempts to position their products, some proper online presence could be improved. This supplier may be best to be contacted via Chinese local trading platform.

3. HYDRA-TEST (Cottingham Engineering LTD)

Active since: 1990s

Location: Kettering, United Kingdom (head office) / Minsk, Belarus (daughter production company)

Types of equipment supplied: transmission dyno test stands, valve body test stands, torque converter repair equipment, valve body repair tools.

About: at this day, Hydra-Test is the only prominent and reliable transmission repair equipment supplier from the United Kingdom. In 2019, the company opened a subsidiary production office to be more competitive in terms of product production cost and be able to deliver most reliable support quality. Valve Body testers by Hydra-Test are known for durability and full coverage of clients’ demands. Hydra-Torque equipment fabricated in the Belarusian division since 2017 has been supplied to various countries, including a heavy-duty application. The team is also open for custom-built solutions and delivers them in exact match to clients’ needs.

Product updates: Hydra-Dyno (launch of transmission dyno production), HTC-S (newest controller generation), 0AM valve body test tool.

ThisUK supplier is well-known for their attitude, constant update of available solutions. Opening a production site in Belarus is also an advancement. Some companies from post-Soviet territories can be barely counted on. However, if guided by European service standard, it is a great combination of affordable price and highest quality of transmission repair.

CHECK OUT PRODUCTS https://go4trans.com/hydra-torque-transmission-dyn...

4. Mustang AE

Active since: 1970s

Location: Ohio, USA

Types of equipment supplied: dyno test stands for a huge variety of applications (including transmission dynos), solenoid testers.

About: on the market for over 40 years this company has launched a series of equipment for various applications, including military sector, heavy-duty equipment, and more. The company aspires to deliver creative thinking to drive continued success. They are one of the leaders in delivering sophisticated dynamometer technologies and advanced engineering capabilities.

Product updates: not recently.

Mustang AE’s growth has been hindered recently but it is a supplier worth referring to at least for comparison. A company with such a serious portfolio that includes emission measurement system fabrication, own design services bureau and more is certain to work on transmission repair clients’ requirements in a diligent way.

5. Extra:

We tried to contact alternative Chinese and USA suppliers to provide more info for consideration here but were treated with silence or an awkward invitation to come to China to see the machine and learn about pricing.

How to repair this transmission (Videos)

RockAuto Auto Parts transmissio being dyno tested

G-TEC: transmission dyno

Powerglide On The Dyno

Transmission dyno upgrade with Hydra-Test HTC-S controller

Transmission dyno at Certified Transmissions

G-TEC: DYNO Transmission Tester for "light" vehicles

How your Transmission was Dyno Tested

Supeflow. Axiline transmission dynamomenter

Instruction manuals and useful links

Link type	Source	Description
pdf	http://promand.com.au	AXILINE 66K TRANSMISSION DYNAMOMETER
pdf	Superflow	Axiline 97000 dyno brochure
pdf	Powertest	Powertest transmission dynos. Product brochure
web	MAE	Mustang MAE transmission dynos
web	Gearstar	Was your traansmission dyno tested

Torque Converter Balancing Unit Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Balancing is used after all components have been replaced and subsequent welding is done. The process of balancing allows transmission service people to find out if there is a bad or uneven weld on the circumference of a Torque Converter. If it is identified, the operator can easily weld on a small amount of material or remove it. Performance transmission and racing transmission specialists pay special attention to Torque Converter balancing.

When you turn the ignition key the Torque Converter starts to rotate together with the engine. Torque Converter of about 250mm in diameter and of about 10 kg in weight imbalance in its RPM can cause such a serious vibration that the entire vehicle will be affected, including fastening elements of the engine and the automatic transmission.

Balancing machine for torque converters allows us to check imbalance of this element with guaranteed accuracy. Precision system implemented in these machines allow transmission repair experts to pinpoint exact place of excessive or insufficient weight.

Vacuum Test Unit Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The Vacuum Test Unit is used to test the vacuum integrity of all Valve Body hoses and valves. This method of Valve Body testing is considered to be quite a traditional testing solution for transmission shops - it is a money-saver which does a straightforward job. At the same time it doesn’t provide the many advantages of the modern sophisticated transmission service tools. Vacuum tester is often used jointly with a Valve Body test equipment for remarkable results.

The vacuum test allows to evaluate the condition and wear of the valve (plunger) in the body of the hydraulic unit. A worn valve or a hole in the hydraulic unit may result in improper operation, reduced performance or malfunction of the automatic transmission. In most cases, it is possible to assess the wear of the hydraulic unit of the automatic transmission without the vacuum test. However, if you have repaired hydraulic unit with the help of special reamers and valves produced by such manufacturers as Sonnax, a vacuum tester is a must because the vacuum test allows you to quickly and easily test for leaks in the channels of the hydraulic unit.

Solenoid Tester Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Many Valve Body problems are due to solenoid issues. Typically, a Solenoid tester is similar to a Valve Body testing unit - it is offered by the same manufacturing companies with similar software and hardware changed to do job only on Solenoids. It comes as an efficient solution to smaller-scale transmission repair businesses looking for a more affordable solution to improve their Valve Body rebuilding quality and general automatic transmission rebuild standards as well.

Solenoid testing machines are used for checking the state of solenoids produced by different manufacturers of automatic transmissions. Separate solenoid test blocks make it possible to run tests for the majority of most popular makes on the actual international market. Modern Solenoid Test machines now typically come as a universal model and allow to cover any transmission specialists’ preferences in transmission rebuilding operations.

Modern Solenoid Test tools allow possibility to run tests at maximally high required temperature and solenoids are tested as they function with the valve body, as originally designed. The automatic transmission solenoid is an electromechanical regulator in the gearbox, in response to the computer impulse it opens or closes the channel in the hydraulic unit to control flows of hydraulic fluid. Solenoids control the hydraulic switching of operation modes in modern automatic transmissions, CVT and DSG. The solenoid is inserted in the channel of the hydraulic unit and is fixed by bolts (or a pressure plate) and at the other end through the plug of the wiring harness it is connected to the electronic control unit of the automatic transmission.

How to repair this transmission (Videos)

RayTech Tester for Transmission Solenoid

Hydra-Test Solenoid test machine guide

Transmission Solenoid Testing (Ohms Law)

Automatic Transmission Basic Solenoid Testing

How to test automatic transmission solenoid status: OK or Bad ?

Hydra-Test HT-SOL 25 - Intro

How to test a Transmission Solenoid

Instruction manuals and useful links

Link type	Source	Description
0	Gears Magazine	Transmission Solenoid Test Methods
0	Gears Magazine	Understanding GM 6T40 Solenoids
0	Gears Magazine	Subaru Lineartronic CVT Lock-Up Solenoids
0	Gears Magazine	Ford Solenoid Strategy Numbers: Is It Necessary to Program?

Valve Body Tester Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In the automatic transmission, the valve body serves as the hydraulic control center responsible for gear shifting and torque converter clutch application. Inside a valve body, one will see a maze of channels, different sets of valves, and a variety of solenoids. These all work together controlled by the transmission control unit or module (TCU or TCM) to direct hydraulic fluid through these passages to the valves activating the required clutch pack or servo to apply or release these elements causing gear changes and torque converter clutch application. Modulation of the components is what provides smooth gear changes over the range of throttle application or driving conditions.

Why is valve body testing important and necessary?

Valve body testing covers a significant range of tasks. Among these, one may distinguish 5 principal ones as below:

Speed up the process of repair of a worn valve body,
Be able to pin-point a source of malfunction within a valve body,
Provide confidence in valve body repair for extended warranties,
Be compliant with stringent quality requirements,
Provide end-of-line testing for a new valve body as a factory product and performance valve body testing.

The only other viable option to test a valve body is to test-in the vehicle, which involves a large amount of labor and technician time especially on newer vehicles where installation and removal of the valve body may require other vehicle components to be removed to gain clearance. Simple remove and reinstallation of a valve body inside a car can take up to 4 hours to complete. If a shop is specializing in transmissions and valve bodies and repair volume is low, this might be an option that works for them, but most shops are competing on price and so the required technician time make s this an expensive option. The real issue with this method is when there is a fault or malfunction that is not obvious and the technician has to perform the install, test, remove, and repair procedure multiple times to try and identify the problem or worn circuit in the valve body. If a shop has any significant volume of transmissions to repair, the technician and owner simply do not have the spare time to do this and needs to avoid time-consuming troubleshooting road tests.

Subsequently, conventional scan tools and pressure gauges do not always suffice to determine what exactly is causing the trouble within your valve body, especially if it has significant mileage. An inexpensive vacuum tester is certainly a must-have for a quick bench test upon tear down. It serves as a cornerstone every time one starts valve body inspection and repair. A vacuum test can identify a worn valve or questionable circuit, but it may be difficult to determine the degree to which a valve, or a bore, is worn and it may not identify the wear as clearly as needed. A valve body tester emulates road conditions and actual hydraulic operation of the valve body in all gear ranges as well as near the normal operating temperature of the valve body. The valve body can be tested at a variety of pressures with temperature control and strict control of solenoid amperage to simulate the hydraulic modulation as gear shifts occur. The performance of the unit under test can then be compared against benchmark data in a graphical or tabular format. This allows a technician to identify faults or questionable data that are not able to be seen in the vehicle. The modern valve body test is a complex and eloquent tool that gives the technician the ability to identify the exact source of trouble, leaving little room for doubt and giving confidence that the repair has been performed correctly.

The ability to provide extended warranties and to keep warranty claims as low as possible have a direct effect on the reputation of a shop. In order to be confident in the repairs to offer these types of warranties it is important that the unit is thoroughly tested using consistent test practices. A shop with high warranty claims, even if addressed and the issues rectified, can suffer from unhappy end customers and this can have a direct effect on the reputation of the shop. Therefore, if one is concerned about delivering the transmission shop’s valve body repair guarantee and protecting the shop’s reputation, quality valve body test equipment is crucial.

Another important factor is compliance with certain requirements for a repaired product. This comes into play if a shop or remanufacturer enters in a contract with larger companies providing multiple repaired or rebuilt units. This is common in fleet accounts where the removal and installation of the transmission is not done by the shop remanufacturing the unit. When doing this kind of work there may be a requirement that repaired or remanufactured units meet a certain quality standard (confirmed by thorough testing).

One more application for advanced valve body testing is end-of-line testing. This is typically larger remanufacturing companies or even OEM that need to make sure that the unit just built is performing as per the specification and there has been no fault during the production process. This can also include performance shops that build valve bodies for racing or for heavy duty / towing applications. The volume may be lower, but the use of a valve body tester is critical in these operations as well.

History and principle of operation of a transmission valve body tester

Valve body test equipment started to become common among transmission repair shops in the early 1990s as valve bodies transitioned from hydraulic cast iron three speed units, to aluminum electronically controlled four speed units. During this pre-digital era the equipment was fully analog with multiple pressure gauges to show readings and even lights with pressure switches to show if there was a minimum amount of pressure in a circuit.Valve body test equipment has started to gain among transmission repair shops of various scales back in 1990s and during that pre-digital era the equipment was, obviously, fully analogous with multiple readings shown on the external gauges.

At that point, the principal components of a valve body tester were the machine itself (mainly a pump and pressure regulation system, the corresponding test plates connecting the test unit to the machine and gauges, and a basic shift controller that would fire the solenoids on or off to achieve each gear). An operator would need to watch the gauges upon a gearshift and make a determination on the quality of the unit based on experience. Nowadays, the data acquisition and processing controller integrated into the testing process plays the key role in modern testing. At that point, the pivotal components of a valve body tester were the machine itself and the corresponding test plates connecting the test unit with the tested element. Nowadays, the data acquisition and processing controller integrated into the testing process plays another vital role. Here we may have a close look at all the three key elements that were specified.

If we break down the key elements for modern valve body test machines, we can see there are three key areas:

1) The principal components of a modern Valve Body testing machine:

The hydraulic pump and motor,
Suction and high-pressure filters,
Input and output pressure transducers,
Heating elements and temperature controllers,
Proportional and gate valves,
Oil tank (to be filled with automatic transmission fluid),
Integrated personal computer or a portable laptop.

Based on this list, the idea is that the system feeds ATF into a valve body under varying pressure and temperature conditions. These would vary to emulate real-life driving conditions.

2) Valve Body and Solenoid test plates and adapters

These adapters emulate the case connection for a valve body or the bore in a valve body for a solenoid and allow the unit to be connected to the test machine. Connection test plates may have orifices for compatibility with certain valve bodies and plumbing to closely emulate how fluid is fed in the vehicle. Connection hoses and cables differ depending on the model. Typically, plates and cables are model specific and it is one test plate and one cable for a certain model of valve body.

3) The control system to drive solenoids and data acquisition for recording and presenting test data.

With the advent of modern valve bodies coupled with mechatronics units, the task of powering and controlling solenoids is not getting easier or less critical. As there is currently no universal tool to test mechatronics components (link: https://go4trans.com/technical-valve-body-articles/advanced-hydraulics-testing-for-valve-bodies-why-there-is-still-no-universal-solution-for-mechatronics-assemblies/), valve body testers are designed to universally test the hydraulic parts of these valve bodies. With modern units, PWM solenoids require a special approach that is vastly different from ON/OFF solenoid testing and for this purpose more complex controller systems and software are required.

Data acquisition is much more crucial with testing of modern valve bodies. The ability to capture data at 500Hz-1000Hz is necessary to comply with up-to-date valve body testing standards. With 500-1000 reading per second, one can be sure that no data will be missing, and the valve body or solenoid faults will be easy to identify.

The acquired valve body data is then compared against benchmark data previously store in the system. This is done via graphical overlay of the tested performance data. With a visual graphical display pin pointing faults can be done quickly and easily.

What types of valve bodies can be tested?

Modern valve body testing systems are built to be universal and are suitable for transmission repair shops across the globe. The testing process itself does not change from a valve body to valve body. All units are tested hydraulically, and solenoids are checked electrically. The necessary part is that the manufacturer has to be able to provide a valve body test plate suitable for a new / particular valve body.

There are a few aspects of testing for various valve bodies worth touching on separately:

1) Latest model Valve Bodies with mechatronics, or TEHCM testing (for a thorough review, read the article: https://go4trans.com/technical-valve-body-articles/a-good-closer-look-into-mechatronics-units-testing/)

Generally, the mechatronic part is omitted from the testing circuit. There are 2 key reasons for this. Firstly, there is no universal tool that can test all varieties of TEHCM applications. Secondly, a transmission specialist really wants to test all parts separately – to be able to identify the valve body fault most clearly without questioning if it is a valve body or a TECHM programming/fault.

Power Test’s Axiline has a solution to test just a few types of TEHCM applications with their WinDyn Test Cube system. There is number of limitations with this system as the system can only test:

-6HP19, 6HP21, and 6HP26 mechatronics by ZF but not all types of these models (with exclusions by years),

- some GM (General Motors) models: 6L45, 6L50, 6L80, 6L90, 6T40, 6T45, 6T70;

- DQ200 (0AM) and DQ250 (02E) among DSG’s.

Another concern is whether this solution is worth the investment as the Test Cube by Axiline is nearly as costly as the valve body testing machine itself. The standard solution is to use corresponding TEHCM tools by OEM’s – like ZF Testman for ZF.

Other manufacturers of valve body testing equipment have omitted the mechatronic part from their test cycle.

2) Solutions for Valve Bodies popular in all countries across the globe

Axiline specializes in the USA market and concentrates on the models that drive on the North American roads: GM, FORD, Chrysler, and Allison. For example, the Axiline solution line for GM is widely used globally on popular models such as 4T65-E, 5L40E, and 6T40/45. Some of the supported models are most common in the US becoming quite old – for example, 200C, 400. Concentration on the USA models is not surprising as the USA car market is the largest world market – however, this leaves transmission repair specialists from other countries of the world not covered.

Raytech or Transpeed, which are China-based, offer solutions based upon models popular on the Chinese roads - although they trade globally and strive to provide solutions across the globe.

Hydra-Test has opted for universality and the solution that covers all of most popular models globally and locally: German valve bodies by ZF and VW; American valve body models by Ford, GM, and Chrysler; Asian transmission valve body models by Hyundai, Kia, Toyota, Nissan, and more.

Kinergo’s Valve Body test machine, an emerging solution from the advanced post-Soviet industrial region, is covering what is in demand and the team provides solutions inspired by other manufacturers.

3) Continually adding new testing adapters and solutions

As a repair technician needing to stay current with the ever changing automatic transmission repair market one would want to invest in a tool that will be on pace with the trends, model updates, and new models of the industry. Therefore, it is vital that the likes of the 9HP by ZF, AC-60E by Toyota, 8 speeds by GM, the 10L by Allison, or latest CVT’s like JF016 are being added to the range of solutions by your supplier of automatic transmission repair equipment.

4) Custom-built solutions

If you are developing your own valve bodies or if you are producing performance valve bodies, it is necessary that the manufacturer of your equipment knows to handle solutions that are demanded by your company. A need for personalized valve body testing can be met with reluctance to take it on or a high cheque. However, for some manufacturers this is a good cause for faster introduction of newly-launched valve body models to their product range. For instance, this is how Hydra-Test took on heavy duty solutions: although the company specializes in the models for light-duty civil vehicles, they have introduced VOLVO CE (Construction Equipment) PT2116-PT2509 and PT1860-PT1861 as there was a demand for this.

How do valve body testers check individual solenoids?

Generally, valve body testing equipment allows for solid verification of solenoid operation. The technician can see how solenoids installed in a valve body perform in the valve body assembly. Here we shall focus on how valve body testers can be used with solenoids separately from the valve body.

If a transmission repair specialist is just beginning to repair and remanufacture their own valve bodies, they may opt for a solenoid tester and valve vacuum tester combination. A vacuum tester is conventional inexpensive tools – Sonnax vacuum tester is the option of preference.

There are several methods of solenoid testing but a most thorough check is with implementation of advanced solenoid testing equipment (check the solenoid testing equipment section). The question comes up on if a transmission technician has to have separate solenoid tester and valve body testing machines? The answer really depends upon the volume or work a shop has. If you can split the time needed to test solenoid and valve bodies on one machine then there are solutions to test both in a valve body tester. However, if the volume becomes such that testing solenoids holds up being able to test valve bodies, then the shop is really in a position of needing two separate machines.

The option of testing solenoids with the valve body testing equipment makes sense when you have lower volumes of work. This feature is easy to add as by default the hardware, software and the controller of a valve body testers is more advanced than that of solenoid testers. They only step needed is addition of solenoid testing blocks with a valve body tester so inquire if your potential supplier has the ability to easily add this feature to the valve body test machine.

Here is an example of the UK’s Hydra-Test add on adapter package for solenoid testing on their VBT Deluxe. A solenoid adapter plate is placed in place of a typical valve body pate and their line of solenoid test blocks fit exactly as they do in the solenoid machine. The solenoids can now be checked hydraulically and electronically with all the same quality of data capture and processing as the valve body testing.

Importance of hardware with transmission valve body test stands

Hardware plays crucial role in reliability of the testing equipment and certainly contributes to having the equipment up to actual standards as time advances. The are many internal components that serve to capture and process transmission valve body operational data. These are the pressure transducers, power supply, transducer distribution board, cabling kit and leads, temperature controller, and so on.

The hardware serves as the control center of a valve body test system and it is the key of valve body performance data processing by using pulse width modulated solenoid outputs, analog inputs, discrete inputs, frequency inputs, analog outputs, temperature sensors – as key data acquisition components.

Most often, suppliers of testing equipment develop and apply their own hardware unless there is a need for some specific solution. An example of past cooperation between companies in the industry was Mustang Dynamometer and PCS (Powertrain Control Solutions). PCS controllers were private labeled for Mustang as a means to support a large variety of transmissions in the mid-2000’s for their tests at the time. However, cooperation between a few parties in not a strategy to last long enough and the best approach is using own solutions.

Hydra-Test has brought the controller development in house with their initial release of their HTC-K controller and more recently the HTC-S controller. This is the latest controller capable of valve body and transmission testing. The hardware components here are built to last with extra protection and convenient modular system, so the system can grow as a customer needs more capability and/or as new units are added and need to be tested.

How to repair this transmission (Videos)

Answermatic Valve Body Test machine

Kinergo Valve Body Testing machine

Hydra-Test Valve Body test machine guide

Hydra-Test Valve Body test machine overview

Hydra-Test 0AM (DQ200) valve body testing on a bench

ZF 6HP19 - valve body testing on Chinese machine

Valve body testing explained

A6MF valve body testing on Chinese tester

Vacuum testing with Sonnax tools

ATS Diesel Valve Body testing on a bench

Instruction manuals and useful links

Link type	Source	Description
web		Buy Hydra-Test Valve Body tester

V4A11 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of automatic transmissions V4A11 - V4A12 for 4WD (RWD- R4A11) drive of Mitsubishi Pajero Mini was designed by the AT (automatic transmission) department of Mitsubishi in 2000 simultaneously with FWD versions F4A11-F4A12. The difference between V4A11 and V4A12 is in slightly higher transmitted torque, but both versions use the same engine (0.7 liters). The 1-liter engine can be used only for F4A12 or R4A12 (AWD- V4A12). The V4A11 \А12 unit is mainly installed on AWD versions of Pajero Mini for a Japanese market. These transmissions were aggregated with a minimum 4-cylinder engine (0.7 liters) The design of all sub-modifications is quite similar, equally reliable, and this transmission goes so long that the cost of the machine at the time the overhaul of the machine becomes comparable to the cost of the bulkhead automatic transmission. The gearboxes were adapted for different engines and different underfoot spaces of the Mitsubishi mini-cars from (eK WAGON to Pajero Mini).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/AWD		3,5	2	SP III

Technical issues and repair guidelines

The repair of these transmissions mainly consists of replacement of the filter and change of the transmission fluid.In most cases, the reassembly of the transmission, cleaning of the valve body and replacement of solenoids are performed by car owners. In many cases, the replacement of this automatic transmission with the used one turns out to be less expensive than its repair.

AS69RC Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

AS69RC is a 6-speed A/T produced by Aisin and initially intended for Ram 3500 HD. This gearbox took place of AS68RC in chassis cab modifications for 2013. It transmits the drive torque equal up to 1150 Nm. In terms of design this gearbox resembles AS68RC. AS69RC is large-sized and more reliable than AS68RC and 68RFE. AS69RC has 3 planetary gear sets, 1 overrun clutch, and electronically-controllable gear switching and the converter clutch.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD/AWD	1150	13	6,8	Mopar ASRC

Technical issues and repair guidelines

Specialists assume that the following service procedures are required for this transmission: change ATF every 30 thousand miles or 2 years, replace gearbox filter every 60 thousand miles or every 4 years. Starting from 2014 the modification AS66RC appeared to replace AS69RC in Dodge Ram trucks.

How to repair this transmission (Videos)

AS69RC Teardown Part

4N71B Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

4N71B 4-speed automatic transmission 4N71B was produced in 1984 for rear wheel drive Nissan 300ZX.This transmission is a successor of very famous 3-speed modification 3N71B. Since 1989 this transmission was modified for Mazda 929 under the name N4A-EL. In 2000 4N71B was used as a basis for updated JR401E, which is used with 3-liter engines V6.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	280	7		AT-Matic J

Technical issues and repair guidelines

This transmission appears in repair services very rarely. Due to its simple design specialists usually just need to replace worn-out spare parts and friction clutches to bring this transmission back to life.

How to repair this transmission (Videos)

Valve Body Shift Kit Installation

Instruction manuals and useful links

Link type	Source	Description
pdf	waghornswood.net.nz	Repair manual E4N71B
pdf	shinseiauto.com	Scheme 4N71B

BW8/12 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Flashomatic automatic gearbox was also named as BW8 (1956-66)/BW12 (1956-71). This gearbox had been actively installed on different models of Packard, Rambler, Studebaker during 1956-71.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		9,8	4,2	ATF Type F

This transmission is considered to be quite durable due to its iron case. The BW-12 was installed on some Ford vehicles in 1973-74.It is a hydraulically controlled RWD gearbox. This gearbox resembles Ford-O-Matic manufactured in 3 different case sizes used from 1951 until 1968) and FMX gearbox (released in 1968), but few of the parts are interchangeable.

THM425 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The THM425 (and later 325) is a 3-speed automatic gearbox designed and released by GM. The structure of the THM425 is based on the THM400; most spare parts in these gearboxes are directly interchangeable and some others can be adjusted with the help of slight modifications. The THM425 was designed for Oldsmobile Toronado and Cadillac Eldorado.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		12,3	6	Dexron II

More lightweight gearbox THM325 took the place of the THM425 in both car ranges in late 1978. Since 1979 and later longitudinal engine FWD cars have been equipped with the THM325. The THM325 was upgraded to THM325-4L with an overdrive added in 1982, but all cars with this gearbox switched to more-common transverse engine mounting in 1986.

How to repair this transmission (Videos)

TH-400 rebuild part 1

TH425 Governor Gear Removal

TH400 Rebuild: Governor

THM250 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic gearbox THM250 is based on the THM350. This gearbox was released in 1974 and was applied in Chevrolet cars. The THM250 was developed and designed by GM as a part of Turbo Hydra-Matic family of automatic gearboxes. When taking into consideration the internal structure of the gearbox, the THM250 is very similar to THM350, apart from the intermediate clutch package with a band adjuster.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		9,5	5,6	Dexron II

Generally, the THM250 was attached to small displacement engines. In 1976 this gearbox was taken out of production and was replaced by the light-duty THM200 transmission. However, the THM250 reemerged in 1979 as the THM250-C as a result of numerous issues withTHM200/200C. The 250C version had a reduced weight thanks to the use of a central gear shell applied the THM350, but with three holes to decrease flywheel mass and the low/reverse piston with eight notches.

Instruction manuals and useful links

Link type	Source	Description
pdf	oldcarmanualproject.com	Repair manual THM250

VT1-27 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

CVT VT1-27T Mini (or general name for this family - VT1F) found application on Mini BMW. In addition to Mini, this CVT was offered to Volvo, Land Rover, Hyundai, but this transmission rarely comes to repair services and its hard to find spare parts for repair of this CVT. The following modification CVT VT2 was a budget-friendly solution. This CVT had been offered to many automakers from 2009 to 2013.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	150	7,6	4,3	Esso EZL799

Technical issues and repair guidelines

This CVT has a typical design (with a solid reserve on transmission components) with a push belt and does not require repair for many years, except replacement of ATF and filter, and later – replacement of Bosh belt. This CVT was developed specially for BMW mini.

Settings of the VT1 control unit are adjusted for preserving expensive cones at low speeds, when the belt and surfaces of cones operate closely to the limit. Cones have wear-resistant cover of operating surfaces with the use of space technologies can not be rebuilt and not supplied to the repair market. CVTs of this generation are very sensitive to the level of ATF, therefore the check of this parameter is very technology-savvy.

Rare overhauls with reassembly of spare parts, wear-out of which leads to pressure losses on friction elements and as a consequence their (frictions) wear-out require the repair kit of gaskets and seals. While maintaining these CVTs experienced specialists replace the filter and change ATF as often as possible to avoid time consuming search operations for spare parts. Simultaneously with change of fluid and filter replacement, it is recommended to check the belt for wear-out of the protector. If there are any suspicions about wear-out, it is better to replace the belt. Even slightly wornout belt increases the risk of slipping (metal-on-metal) in situations with usual "non-sporting" acceleration in order to outrun the truck ahead. Generally, this CVT is quite comfortable and “invincible” under the condition of proper care. It is one of the top CVTs on the market.

How to repair this transmission (Videos)

Replacing Belt part 1

Belt replacement pt2

Mini Cooper CVT overview

ZF VT1 CVT Transmission Stepper Motor

Rover - Service Insight - VT-1 Automatic Transmission

Mini CVT transmission teardown

Mini CVT teardown test clip

Mini Cooper cvt adaptation

722.8 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 722.8 transmission (CVT) has been produced since 2005 and mainly used on Mercedes А170. It is also installed on other cars of А series with engine capacity from 1.5 to 2.0 liters.

The design of this CVT is based on model patent CVT with the "push" belt produced by Bosch-Fondorn and the most expensive spare part – the belt itself. This CVT is the analog and competitor of a Japanese CVT JF011E.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	300	7	6	236.20

Technical issues and repair guidelines

Overhauls of old cars with this transmission usually require the kit of spare parts (gaskets and seals from Autoline) and the kit of friction components. Friction components are replaced quite often in the process of the transmission reassembly, because the 722.8 unit is removed together with the engine, and easily wornout frictions already have a negative impact on the clutch. Driving with worn rings and seals lead to oil starvation and premature burning of quite durable friction components.

The fluid in 722.8 should be changed timely together with filter. The fluid and its purity are critical for cones and belts of this CVT, therefore for old 722.8 units, it is recommended to add the fluid at every opportunity and check its level with a service gauge.

The electrical part always causes a lot of problems in Mercedes transmissions. The board was made by the partnering company of Mercedes and after the warranty period you can face such problems as contaminated fluid (metal dust) and overheating. Steel dust magnetized on sensors lead to their failure.The belt is another vulnerable place in this advanced unit. Mercedes used the belt with additional resource on durability and reliability for its CVT.

Shaft bearings are the first among hard parts to get out of order (like with Jatco CVTs) because of lateral dynamic loads. The end of shaft-cones service life means the end for the CVT unit itself. The lifespan of bearings is highly dependent on the fluid cleanness, and most importantly - on its operating temperature.

How to repair this transmission (Videos)

Gearbox control unit sensor

Instruction manuals and useful links

Link type	Source	Description
web	actronics.eu	Mercedes-Benz Temic VGS (722.8)
pdf	autogear.fi	Scheme 722.8

U150E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic gearbox U250E is installed on all FWD and AWD vehicles produced by Toyota and Lexus with engine capacity from 2.5 up to 3.5 liters.

The whole range of U150 is more comfortable and economically viable (and high priced) alternative to "invincible" 4-speeds U140-U240. The 6-speed automatic gearbox U660 was produced in 2007 for Toyota Camry and Lexus car drivers who are more demanding of gear shifting process. The U150, 151 – can transmit a bit higher torque at low speeds than U250E. The U151F unit is intended for 6-cylinder full-wheel drive vehicles- RAV4, Highlander, Sienna.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD/AWD		9	4	Toyota Type T-IV

Technical issues and repair guidelines

Major repairs of U150-250 units almost always starts with the torque converter repair and spare parts replacement ( lockup).The set of pistons is also included in the typical list of spare parts for repair of this transmission. The pairs of firctions (steel disks in the Overdrive drum) is the first component to get burned in these units. The second spare part to be considered is burnt Direct clutch (happens if the vehicle continuously operates with burnt Overdrive frictions).

The kit of friction components is ordered as frequently as the Overhaul kit especially when repair specialists have to deal with gearboxes with burnt ATF. Early wear of the Overdrive friction clutch is linked to the design of the rear cover, which plays the backup role for this clutch cover (drum). The other common issue for majority of these automated gearboxes is related to problems with pump seals and axles. The pump bushing is usually ordered together with abovementioned spare components. The main symptom of the problem is the ATF leakage through the pump seal. The main cause of this problem is an aggressive driving style and a long-term driving with burnt torque converter clutch.

Electrics in U250-150

Problems with electrical parts in U250 and U151 gearboxes are often triggered by issues with the valve body.The valve body U250 (2002-2004) frequently could not maintain set parameters, old (massive) solenoids couldn’t cope with tasks, therefore the valve body wears rapidly. In 2005, the valve body was updated after replacement of solenoids (the valve body itself was left unchanged). Solenoids for valve bodies of U250 and U151 units ranges for different cars and selected according to VIN-code of the car.

Peculiarities of early repairs of U250 and U151 units are related to the fact that the “electric clutch” was widely used in 2000-th and engineers refused from the "full-proof" comcept and did not limit capacity of the driver related to the aggressive driving style, that may lead to burning of friction components and other elements.

How to repair this transmission (Videos)

U151 Teardown

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual ECT U150E
pdf	www.at-manuals.com	Repair manual U150E
pdf	www.at-manuals.com	Scheme U150E
web	www.at-manuals.com	Solenoid identification U150E
pdf	Sonnax	Valve Body Layout U151E/F, U250E
pdf	Sonnax	Vacuum test valvebody U151E/F, U250E

B7TA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic 4-speed transmission B7TA was designed by Honda specialists in 1996. It is intended for front-wheel drive Honda and Acura vehicles.

This modification of automatic transmissions can be installed on 6-cylinder engines with the capacity not higher than 3.5 liters. In the process of operation this transmission made a good impression. Due to its simple design, this transmission is distinguished by its reliability and durability. The maintenance service for this transmission is not complicated.

HONDA ODYSSEY 2.3L; V6 3.5L; Honda B7TA

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		7,1	2,9	Honda Z-1

Technical issues and repair guidelines

After running 50 thousand kilometers it is required to change the oil with a filtering element. The car owner can perform this procedure by himself even with a limited experience in this field. B7TA has no planetary gears that allowed engineers to simplify the design of this transmission. It had a positive impact on the level of durability and reliability of this automatic transmission. It is not unusual, when well-timed maintenance and proper usage helps this transmission to cover 400 thousand kilometers without major repairs. Transmission specialists recommend warming up of the oil in this transmission in winter. It can be done the following way: shift the selector lever to the Drive position and hold the brake pedal depressed for about 30 seconds. This measure will help to warm up the transmission oil and prolong the trouble-free operation of the transmission. It should be also kept in mind that immediate accelerations after the start of the movement and gear-shifting in the manual mode may be harmful for the transmission.

The list of common problems with B7TA includes issues with rubber gaskets which lose their elasticity after running 100-150 thousand kilometers that leads to oil leakages. In this case the repair procedure lies in replacement of these gaskets.

How to repair this transmission (Videos)

B7TA Transmission - Honda Odyssey

Instruction manuals and useful links

Link type	Source	Description
pdf	drive.google.com	B7TA Manual

AB60F Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission AB60F (-Е – for rear drive) or AS68RC for Dodge RAM of the class extra heavy duty, Aisin name TB-68LS. This transmission was produced by Aisin Co since October of 2007 and paired with the engine V8 (5.7 liters) for 4WD SUVs such as Land Cruiser, Tundra, Sequoia, Lexus LX570.

This reliable 6-speed transmission with "invincible" design tested on rear-driven predecessors А760-960 and on 8-speed АА80Е released the year before (2006). The main competitive product of this transmission is ZF6HP32.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD/AWD	680	11,8	4,6	Toyota WS

Technical issues and repair guidelines

Electrical components in this transmission is extremely sensitive to the transmission fluid status. The oil change requires specific knowledge and experience.

During the overhaul the following parts are ordered for reassembly:the kit of gaskets and seals as well as kit of frictions.Friction components in this transmission are not complex and serve reliably till the end of the transmission resource. Frictions are usually changed as a result of operation with worn-out rings, bushings and sealing. First of all the, clutch drum Forward (С1 gears 1-2-3-4) gets burnt. All overhauls of the AB60F unit still involve the torque converter repair with replacement of the lockup clutch, replacement of burnt clutch, replacement of the filter and full spare parts kit: seals and gaskets made of rubber and paper.

The valve body design is similar to the valve body of the А960Е transmission and it should be expected that typical problems with electrical components may be the same (after the mileage higher than 200 thousand kilometers without timely change of the fluid and filter replacement) wear-out of channels of linear pressure solenoids. Aisin 6-speed transmissions also have the mode of regulated torque converter lockup slippery, but in contrast to 6НР26-32, here the lock device turns on much later (starting from the 3-rd gear) and have reduced impact on the friction.

Almost all solenoids (in comparison with the valve body in А960) functionally remained unchanged, except for linear solenoids SLU, SLT, SL2 in some modifications. Dirt in ATF damages the valve body and solenoids, therefore cleaning of these components is usually planned as the first stage of the transmission maintenance. During the first years after the transmission release automakers usually modify valve bodies, replace solenoids and change settings of ECM program. Therefore, it is recommended to monitor software changes, which may solve some problems in shifting.Mud accumulation in the valve body and solenoids as well as wear-out of rings lead to lower pressure in the Forward drum that results in premature burning of frictions with steel disks (Forward-C1) and corresponding Forward pistons.

How to repair this transmission (Videos)

AB60 Toyota Tundra Valve Body Removal and Installation

Toyota AB60E/F Power flow

AB60 Valve Body Removal and Installation

AB60F, Code P0983

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme
web	www.at-manuals.com	Scheme AB60E
web	www.at-manuals.com	Solenoid application chart
web	www.at-manuals.com	Stall test
pdf	Sonnax	Valve Body AB60E
pdf	drive.google.com	AS68RC manual

Allison 2000 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The Allison 2000 series includes modifications 2100, 2200 and 2300. This type of transmission was designed for light commercial vehicles operating in sectors of transportation and public transport. These transmissions are equipped with a turbine-driven power take-off mechanism with the N-locking option, and with a parking brake. Transmissions of 2000 series may have up to 6 gears, including overdrive, and be equipped with an advanced electronic control system of the 5-th generation, which provides more efficient operation and more diagnostic capabilities. These transmissions are reliable and highly efficient and can transmit power equal up to 224 kW ( 300 HP) in modifications with narrow or wide ratio coverage. As a rule these transmissions are used for commercial vans, drop-side trucks with a manipulator and all kinds of special equipment with a load capacity up to 13.6 tons ( 3000 lb). These transmissions are installed on almost all brands of trucks, buses produced in Europe (except MAN), Korea, and China. The instantaneous connection between the engine and the gearbox ensure precise modes of operation regardless of the cargo condition and the road quality.

Accurate gear shifting without interruptions of power ensures the best speed characteristics and fuel economy. Fully automatic transmission allows the driver to pay more attention the driving process that is more important in difficult and tedious road conditions. The transmission electronics can be programmed to prohibit the vehicle movement when the auxiliary equipment is used. Consequently, the auxiliary equipment will be inaccessible when the vehicle moves. This feature provides additional security in operation.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT		841	14	10	Allison TES 295

Technical issues and repair guidelines

The main repair problems are related to the auxiliary power take-off equipment, torque dividers, and the main one – the cooling process or heat exchanger. Designers of these transmissions quite consciously reduced the transmission resource by means of cooling.

There are 3 main problems related to valve bodies of Allison 1000/2000/2400:

1. Sticking E-shift. When the valve sticks TCM detects that the pressure sensor doesn’t change the status and sets the trouble code P0872- after that the gearbox switches to the failsafe mode.

2. F-trim valve sleeve. The inside diameter of the sleeve wears out, leading to the torque converter clutch surge and trouble code P0741 – indicating the torque converter clutch slipping. . When lock-up stops operating and the P0741 code sets, the torque converter can overheat the ATF, causing damage to the torque converter and rapid deterioration of the ATF.

3. Warped castings. Valve bodies for these transmissions do not have separator plate gaskets, therefore it is required that two halves of the valve body should be flat sanded for protection from cross leakages. In this case locating pins should be removed to flat sand the valve body.

How to repair this transmission (Videos)

fluid and filter change

Allison Transmission Assembly

Instruction manuals and useful links

Link type	Source	Description
web	all-trans.by	Identifying Allison 1000/2000/2400 Valve Bodies

POWERGLIDE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The Powerglide is a two-speed automatic gearbox constructed by GM. This gearbox was mainly installed on Chevrolet vehicles (1950-1973) and on some Pontiac cars. The gearbox was uncomplicated and extremely reliable, that gained trust of customers. In spite of its old-fashioned construction Powerglide is still popular in drag racing (as well as in mud racing) because it is not complicated and robust.

Technical issues and repair guidelines

How to repair this transmission (Videos)

Powerglide Transmission Cutaway

LEARN TO REBUILD THE POWERGLIDE

Instruction manuals and useful links

Link type	Source	Description
web	Sonnax	Understanding & Overcoming the Powerglide Servo Pin Bias Effect

FMX Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The FMX is a fully automatic 3-speed gearbox, ensuring automatic up-shifts and down-shifts via the 3-forward gear ratios. This gearbox also includes manual selection of first and second gears. It is reported that FMX combines in itself the best features of MX and FX modifications.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		10,4	5	Type F

Technical issues and repair guidelines

This is a hydraulically controlled RWD gearbox. In terms of design this unit is close to BW8 and BW12, but spare parts are not interchangeable. FMX consists of the following main components: torque converter, oil pump, input shaft, rear-clutch, front-clutch, compound planetary gear set, rear band, one-way clutch, rear support-oil distributor and parking gear, governor, output shaft, vacuum diaphragm, control valve body, front band. This automatic gearbox was used during 1968-81 in many Ford cars.

How to repair this transmission (Videos)

FMX Transmssion part 1

FMX transmission part 2

Rebuild the Ford FMX Transmission

Instruction manuals and useful links

Link type	Source	Description
web	Wikipedia	Ford FMX
pdf	forelpublishing.com	Diagnosis and service FMX Transmission
0	makcotransmissionparts	Scheme FMX

U540E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed FWD automatic transmission U540E was designed by Aisin in 2000 on the basis of the famous A4LB-1, which went out of fashion by that time. The transmission A4LB-1 also was modified in 2002 and a new modification can be found on different cars worldwide.

This automatic transmission has two names - U540E (according to Aisin Co), and Daihatsu gave different names to its sub-modifications: A4Q, A4P, A4L, A4G, ..., depending on the car model. The U540E was upgraded with several hydraulic control solenoids, the valve body and electrics, and the new filter for the valve body.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		6,2	4	Toyota Type T-IV

Technical issues and repair guidelines

This transmission is very reliable as the most of Aisin transmissions. For many years of operation, it only requires change of oil and filter replacement, however it can cover the distance of 150-200 thousand kilometers even with an old filter. For the overhaul of this carefully adjusted transmission, specialists usually order the repair kit of gaskets and seals, which is mainly needed for reassembly of contaminated valve body and replacement of worn out rings causing the burning of frictions.

The kit of all friction clutches is usually ordered together with the repair kit. Frictions get burnt for various reasons, but one of the most popular ones is related to insufficient oil pressure, caused by:

1. worn-out teflon and rubber rings

2. dirty wedging valves of the valve body

3. dirty valves of solenoids

4. faulty electrics of the solenoid or wiring of solenoids

5. clogged filter

This transmission can be rarely met in repair services, all spare parts for this transmission are considered to be rarity and there is no much statistics related to its repair.

Instruction manuals and useful links

Link type	Source	Description
pdf	alltranz.co	Scheme U540E

K410 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TOYOTA K410 / K411 / K41A / K41B / XA-10LN

Aisin developed the “200” series (K210) of CVT transmissions in 2002. This gearbox was intended for cars with 1.0-1.3 liter engines. The K210 had been produced and installed on some Toyota cars for the domestic market of Japan before 2015.

Nevertheless, this series was not very successful – the CVT was larger than initially planned; it turned out to be not very convenient for underhood space of small cars. Therefore, in 2004, Aisin started

developing a new “400” series on the basis of the K210. The K410 modification was smaller in size, lighter weight, and had enhanced fuel economy in comparison with the “200” series. Toyota considered the K410 to be an ideal CVT solution for small cars with 1.0-1.3 liter engines. This transmission is still applied in numerous Toyota cars (including cars for the European market).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	145	8	5	Aisin CVTF7004, Toyota 08886-02105

In October 2008, Aisin launched production of the CVT transmission named K41A. This transmission was designed on the basis of the K410 modification and was specifically intended for application on cars Toyota IQ. The main difference between these two transmissions lies in the fact the differential in K41A was moved forward (in contrast with K410). This measure made it possible to reduce the size of the CVT for installation on limited underhood space of Toyota IQ (with 1.0 liter engine).

In April 2009, the CVT modification K41b was launched in production. The main peculiarity of this transmission is higher torque transmission capacity. Therefore, this gearbox could have been used for Toyota IQ with more powerful 1,3-liter engine.

In October 2010, Aisin engineers came up with a new CVT solution for the “400” series – the modification K411. The main difference of the K411 transmission from the 410 version is a significant fuel economy, which is achieved by actuation of an active clutch, when starting a car, and thanks to a new control mechanism (flex start control).

In 2007, Aisin produced a new modification of the K410 transmission, which was named as XA-10LN for external markets (not for Toyota cars). This CVT was successfully applied in Suzuki cars (Suzuki Splash and Suzuki Swift). These Suzuki models were sold in the domestic market of Japan.

In the European automotive market, K410/K411 CVTs were installed only on Toyota IQ (K41a and K41b) and Toyota Verso-S/Subaru Trezia (K411). Cars equipped with CVTs K410 and K411 were not sold in the North America (USA and Canada). Cars with these transmissions are quite popular in Australia, New Zealand, and some countries of Southeast Asia.

Typical problems

Typical problems which occur in this range of CVT transmissions include the following:

1) ATF contamination

2) K410/K411 CVTs often get overheated (especially in winter time)

3) Damage of bearings

4) Seal Clutch leakages

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mazda	DEMIO	07-14	CVT FWD	L4 1.3L 1.5L
Subaru	TREZIA	12-13	CVT F/4WD	L4 1.5L
Suzuki	SPLASH	08-14	CVT FWD	L4 1.2L
Toyota	IST	07-16	CVT F/4WD	L4 1.5L
Toyota	PORTE	11	CVT FWD	L4 1.5L
Toyota	RACTIS	06-13	CVT FWD	L4 1.5L
Toyota	SIENTA	03-15	CVT FWD	L4 1.5L
Toyota	VITZ	05-16	CVT FWD	L4 1.5L

VT20E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The CVT transmission VT20E was used for FWD Opel Vectra of English and German assembly with engine capacity equal to 1.8 liters. The VT25E modification found application in American FWD Saturn VUE and Ion (2.2 liters capacity).

This CVT equipped with a push belt is perfectly adjusted, therefore it rarely gets in repair services. During the first 150-200 thousand kilometers of exploitation, drivers just should not forget to replace filters and change transmission fluid in a timely manner (depending on the driving style).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	175	6,5		VTF DEXRON CVT

Technical issues and repair guidelines

A minimum set of procedures during the overhaul of these CVTs includes the following:

- Belt replacement

- Replacement of all spare parts, gaskets, seals, sealing strips, rings, which often include two pistons

Friction elements of Forward pack often get burnt, including a bearing disc and pistons, the whole set of frictions gets replaced.

Problems of “old” VT25E:

- Valve Body, VT25E CVT.

- Planetary gear, Reverse (6 Gear) .

It is required to replace CVT when cones get worn out (because of aggressive accelerations "at a cold motor" and driving with contaminated oil).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Opel / Vauxhall	VECTRA	02-04	CVT FWD	L4 1.8L

How to repair this transmission (Videos)

Repair cvt VT25-E/VT20-E, Saturn, Opel

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme VT20E
pdf	www.at-manuals.com	Scheme VT25E

U660E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission U660E designed by Aisin in 2006 for FWD cars Lexus ES350, as well as for the luxury 6-cylinder models (Camry, RAV4, Avensis) for 3.5 lit. The unit was paired with the V6 engine.The U660F unit is intended for AWD crossovers and sedans. The U660 unit is a competitor of ZF 6HP26. In 2009, the U660 unit was complemented by U760E model cured from "common problems" and intened for a bit lower torque from the engine (up to 2.7 l). After some period of time the U761E sub-modification was released for less powerful engines with 2.0-liter capacity. Repair parts for this gearbox are the same as for U760. Among the market competitors of the U760 unit, specialists point out the ZF 6HP21 unit.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/AWD		6,5	2,8	Toyota Type WS

Technical issues and repair guidelines

Friction lining of the lockup unit is not the most crucial problem for driving, but it is critical for the “health” of this transmission. The torque converter is the main "contaminator" and the source of all problems of clogged valve body and solenoids. This gearbox usually covers 200 thousand kilometers, but the driver can significantly cut its service life by an aggressive driving style. Almost all major repairs of this gearbox include the torque converter repair. The torque converter repair with replacement of worn-out friction lining every 150-250 thousand kilometers (depending on the driving style) allows saving of some money on the valve body replacement.

According to judgement of experts, the most common problem of the U660E unit is related to the main housing bearing, which is attached to a “weak” circlip. The drum of Direct package is one more problem of this gearbox. Many gearboxes with short mileages (only70-100 thousand kilometers) were handed in for the overhaul and replacement of burnt clutch cover С1-С2 - Drum (Direct) in the assembled condition. Another issue is related to wear-out and burning of frictions in braking packages B1-B3 (gears 2 and 6). The most frequently replaced component is a set of frictions in the package C1/C2 (gears 1-4). Generally the whole set of friction components is replaced.

Valve body and solenoids in U660E

The most common problem for all 6-speed automatic gearboxes is the worn valve body. The problem with the valve body, which operated with damaged torque converter lockup and contaminated ATF, is related to wear-out or slagging of channels and plunger-valves of the valve body. The most frequently replaced component in the electrical part is the selector position plate with temperature sensors. The overheated temperature sensor is often considered to be the reason of the valve body malfunction. The first reason of early issues with electrical components (before covering 200 thousand kilometers) is the automatic transmission overheating. Almost each overhaul of overheated U660E transmission is accompanied with the order of pistons kit. The list of spare parts that may be damaged in this sophisticated gearbox as a result of neglected bearing vibrations is quite large (crown gear, sun gear, planetary gears, differential, pistons).

It should be taken into account, that all abovementioned problems with the U660 unit are common for very old or quite worn-out automatics. A high percentage of cars equipped with U660 serve before covering standard 200 thousand kilometers (in many cases even longer) without any repairs under the condition of timely ATF change and filter replacement.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	ES	06-16	6 SP FWD	L4 2.0L 2.5L V6 3.5L
LEXUS	RX	08-15	6 SP F/4WD	V6 3.5L
Lotus	ELISE	12-15	6 SP RWD	V6 3.5L
Lotus	EVORA	10-16	6 SP RWD	V6 3.5L
Toyota	ALPHARD	08-14	6 SP F/4WD	V6 3.5L
Toyota	AVALON	07-16	6 SP FWD	V6 3.5L
Toyota	AVENSIS	08-16	6 SP FWD	L4 2.2L
Toyota	BLADE	08-12	6 SP FWD	V6 3.5L
Toyota	CAMRY	06-16	6 SP FWD	L4 2.0L 2.5L V6 3.5L
Toyota	ESTIMA	06-16	6 SP F/4WD	V6 3.5L
Toyota	HIGHLANDER	09-16	6 SP F/4WD	L4 2.0L V6 3.5L
Toyota	MARK X ZIO	07-13	6 SP F/4WD	V6 3.5L
Toyota	RAV4	12-16	6 SP F/4WD	L4 2.0L 2.2L
Toyota	SIENNA	10-16	6 SP F/4WD	V6 3.5L
Toyota	VANGUARD	11	6 SP F/4WD	V6 3.5L
Toyota	VENZA	08-16	6 SP F/4WD	V6 3.5L
Toyota	VERSO	09-16	6 SP FWD	L4 1.6L 2.2L

How to repair this transmission (Videos)

U660E / U760E Gear Set and Components

U760E with code P2716

U760E TCM

U660E Intro ATRA

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual U660E/F
pdf	www.at-manuals.com	Scheme U660E/F
web	www.at-manuals.com	Check Balls U660E
web	www.at-manuals.com	Stall test U660E
pdf	Sonnax	Valve Body Layout U660E/F, U760E/F

U340E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearbox Toyota U340 (U341) has been used since 2000 on FWD Toyota Avensis, Corolla etc. with engine capacity up to 2 liters. One more leading transmission which is commonly met in repair services.This transmission was designed together with U140\ U240 (and identical in design) and was a very popular transmission in the field of repair among Aisin gear shifting units. The modification U341E provides higher torque, therefore it is used in engines with higher operational capacity Celica (1.8 l), the U341F unit is the version for four-wheeled vehicles (4WD).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		8	2,9	Toyota Type WS

Technical issues and repair guidelines

The whole mechanical and hydraulic part of these transmissions is very robust and the service life before the 1-st major repair is above 200-300 thousand kilometers depending on the driving style of auto users. During the first years U340-341 units require timely change of fluid and filter replacement. After some period of operation and due to frictions wear-out (torque converter in particular), the fluid gets contaminated more rapidly and that results in more frequent ATF change. Frequent change of automatic transmission fluid postpones the replacement of the torque converter lining. One of the most common problems is the oil leakage from the pump seal located between the gearbox and the torque converter. The seal is changed together with the bushing.

One of the most common parts to be replaced in new units (produced since 2009) is the EPC solenoid, which operates in much more intensive way than others. This transmission gets out of order after continuous operation in contaminated ATF with worn-out rings and seals. Timely change of ATF and repair of rings included in the repair kit makes it possible for this solenoid to operate during the whole period of the transmission usage period.

Typical issues with valve body and solenoids in U340

The electrical components of this transmission are quite durable, therefore the whole U340 unit may be considered as a very reliable transmission. However, during each disassembly procedure of this gearbox, specialists usually rebuild and clean the valve body and solenoids, which get damaged because of contaminated ATF. The clogged valve body may lead to unpredictable slippage in the package, where the fluid is not transmitted through corresponding valve body plunger. Long-term operation of this transmission with such problem leads to premature wear of practically “invincible” friction components in this unit.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Toyota	ETIOS / VALCO	13-16	4 SP FWD	L4 1.2L 1.5L 1.6L

How to repair this transmission (Videos)

U340E Corolla Valve Body Problems

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual U340
pdf	www.at-manuals.com	Manual U340e
pdf	www.at-manuals.com	Scheme U340E
web	www.at-manuals.com	Stall test U340e
pdf	Sonnax	Valve Body Layout U341E/F
pdf	Sonnax	U341E/F TCC Slip Diagnosis

U140E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Transmission repair specialists frequently have to deal with repair issues in the 4-speed automatic transmissions U140E, U240, U241 and the entire range of these transmissions from Aisin Co. Aisin engineers wanted to design the U140E unit with a potential extension to 5 speeds.In 2000, more enhanced modification named U240 was introduced and a lot of U140\ U240 automatics found application in the whole range of popular Toyota cars at the auto market in Japan.

The U241E (U240E) transmission has been operating safely since 2000 on the front-wheel (four-wheel drive) middle class cars with engine capacity from 2 up to 3 liters.The structure of these automatic units is so robust and sophisticated that even the presence of some soft spots (such as the third planetary gear) does not prevent U240-241 transmissions from being installed on very popular Toyota cars.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/AWD		9,5	4,2	Toyota Type T-IV

Technical issues and repair guidelines

The risk group of car with this reliable transmission includes heavy cars with 3-liter engines, where gearbox components operate under heavy loads and the 1-st overhaul may occur even before the car travels 200 thousand kilometers. The first component to be repaired is the torque converter. In "old" U140 units transmission specialists have to pay closer attention to the output planet, which may have some issues related to the damage of pinion-satellites axles caused by critical loads. The sun gear gets damaged together with satellites of the planetary gear. At the following stage of damaging process, fragments of the damaged planetary gear crush the rear planetary gear of the U140 unit.

The back cover is the second problematic place for this transmission: it performs a support function in U140-240 design. This issue is common for high-power engines both in RAV-4, and in Camry, Lexus RX300. According to the statistics change of frictions and steel disks in the Direct package is performed 3-4 times more frequently than in any other package.

One more frequently replaced element in the Direct clutch package is the rubber-covered piston with a holder. The rubber gets damaged very fast failing under higher temperatures and dry functioning with jittering. When the pump bushing gets damaged it should be repaired together with the torque converter. The typical problem of the ECU during first years of operation – non-soldered contacts, causing unpredictable burning of packages and pressure jumps. Almost each overhaul includes a preventive change of the pump cup seal on the left side and the left semi-axle seal on the housing side.

The 4-speed automatic transmissions U140E , U240 , U241 from Aisin Co traditionally have very reliable and persistent elecal components. Specialists almost every time are restricted to the repair and cleaning of the valve body and solenoids without any expensive replacements. The repair of old valve bodies involves cleaning of soot deposits and rebuilding of channels used for movement of valves.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	ES	99-02	4 SP FWD	V6 3.0L
LEXUS	RX	98-03	4 SP F/4WD	V6 3.0L
Toyota	CAMRY	02-03	4 SP FWD	V6 3.0L
Toyota	ESTIMA	00-06	4 SP F/4WD	L4 2.0L V6 3.0L
Toyota	HARRIER	00-03	4 SP F/4WD	V6 3.0L
Toyota	HIGHLANDER	01-07	4 SP F/4WD	L4 2.4L V6 3.0L
Toyota	KLUGER V	00-03	4 SP F/4WD	V6 3.0L
Toyota	WINDOM	00-02	4 SP FWD	V6 3.0L

How to repair this transmission (Videos)

U140 Teardown Inspection

Part 1-4 2002 Lexus RX300 U140

Part 2-4 2002 Lexus RX300 U140

Part 3-4 2002 Lexus RX300 U140

Part 4-4 2002 Lexus RX300 U140

Instruction manuals and useful links

Link type	Source	Description
pdf	Valve Body Pro	U140 Shifting Pre Info
pdf	www.at-manuals.com	Scheme U140
pdf	www.at-manuals.com	Manual U140
pdf	Sonnax	Valve Body Layout U140E/F, U240E, U241E
web	Sonnax	Toyota U140E Detailing

TF70SC Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission AT6 (TF-70SC) from Aisin Co was designed in 2006 for FWD Peugeot cars of the middle class with the engine from 1.6 to 2 liters. This transmission has the torque capacity of up to 220 Nm (according to Aisin). After a long testing this automatic transmission was launched in the mass production in 2009, but was produced not as actively as the TF80 transmission unit. It was developed for Peugeot-Citroen cars on the constructive basis of TF-80SC (AM6 High torque capacity- up to 400 Nm). Inner parts of this transmission are similar to TF60-SN. Aisin name is AWF6F25.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD	220	6,1	3,2	Тойота WS

Technical issues and repair guidelines

The transmission AT6 has an electronic control integrated in the design of the transmission. One of the features of these automatic transmissions is the forced control of the torque converter lock-up. This feature, on the one hand, gives an increase in efficiency and rapid acceleration with fuel economy, but, on the other hand, it significantly loads the torque converter and the valve body. In previous versions of transmissions it led to the rapid wear-out of the valve body and the breakdown of solenoids. The transmission is designed as an "invincible" solution and operates till the old age of the car, when the transmission repair no longer makes sense. But violation of simple rules of operation for this automatic transmission can lead to the overhaul only after 150-200 thousand kilometers.

Repair procedures and typical problems

For the first overhaul specialists order the Repair kit of gaskets and seals. This repair kit is ordered mainly because of teflon rings, which wear out primarily from exploitation with contaminated oil and overloads.

The chain of malfunctions starts with the clogged valve body and solenoids, which do not transmit enough oil to the line of one of the packages, therefore the transmission shifts gears with a delay or a kick. One of the typical problems in modern 6-speed automatic transmissions, and in the TF-80SC in particular, is related to the valve body. The valve body is extremely sensitive to the friction suspension from the torque converter in the ATF. Frequent oil changes facilitate the valve body self-cleaning. But now the valve body itself has become almost invincible because all soft spots related to channels transmitting contaminated oil and the plunger with valves have become the part of the solenoid design.

It should be borne in mind, that the higher the wearout level of rings and rubber gaskets, the more ATF should be transmitted by the pump through valves of the valve body in order to compensate losses. Therefore solenoids operating in heavier oil current wear out much faster. For this reason, each reassembly and replacement of solenoids should be accompanied by replacement of spare parts.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Beijingauto	X65	15-16	6 SP F/4WD	L4 2.0L
Citroen	C4	10-16	6 SP FWD	L3 1.2L L4 1.6L 1.8L
Citroen	C4 LOUNGE	13-16	6 SP FWD	L4 1.6L 2.0L
Citroen	C5	09-16	6 SP FWD	L4 1.6L 2.0L 2.2L
Citroen	DS4	11-16	6 SP FWD	L4 1.6L
Citroen	DS5	11-16	6 SP FWD	L4 1.6L
Dongfeng	AX7	14-16	6 SP FWD	L4 2.0L 2.2L
Dongfeng	B20	16	6 SP FWD	L4 2.0L
Dongfeng	L60	15-16	6 SP FWD	L4 1.8L
DS	DS5 LS	14-16	6 SP FWD	L4 1.6L 1.8L
Fiat	500	10-16	6 SP FWD	L4 1.4L
Fiat	500L	14-16	6 SP FWD	L4 1.4L 2.0L
JEEP	RENEGADE	15-16	6 SP FWD	L4 1.7L
MINI	COUNTRYMAN	2012	6 SP FWD	L4 1.6L
MINI	ROADSTER	2012	6 SP FWD	L4 1.6L
Peugeot	3008	09-16	6 SP FWD	L4 1.6L 2.0L
Peugeot	308	09-16	6 SP FWD	L4 1.6L 2.0L
Peugeot	408	12-16	6 SP FWD	L4 1.6L 2.0L
Peugeot	5008	09-16	6 SP FWD	L4 1.6L
Peugeot	508	10-16	6 SP FWD	L4 1.6L 1.8L 2.0L
Peugeot	RCZ	09-15	6 SP FWD	L4 1.6L
Volvo	S60	15-16	6 SP FWD	L3 1.5L L4 2.0L

How to repair this transmission (Videos)

TF-72SC Teardown

AA80E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 8-speed automatic gearbox AA80E (TL-80SN for Lexus) produced by Aisin Co has been installed since 2007 on RWD Lexus LS460 (IS, GS460) and Toyota Land Cruiser and Crown Majesta with engines V8 from 4.6 up to 5.0 liters. The modification АА80F is used for AWD LS460. The maximum torque is up to 550 Nm. In terms of design, this transmission is related to TR-80SD (0С8).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	AT	RWD/AWD	550	11,3	3,7	Toyota WS

Technical issues and repair guidelines

With regard to mechnical components typical problems usually occur in the bushing and the pump seal, which are the first to be affected by the torque converter (TC) lock-up wear-out and overheating. The oil leaks via the seal of pump/TC is the the first signal for diagnostics, cleaning of the valve body, and the TC repair. Further operation with such leakages may result in the necessity for the pump bushing replacement, and in some cases replacement of the pump itself.

In the electric part, the first level repair consists of the valve body cleaning and replacement of solenoids. As in many of Aisin automatic transmissions, the torque converter lock-up solenoid SLU is the first to wear out, because this solenoid operates with all contaminated and overheated oil from the worn-out torque converter. Another problematic area is the main pressure solenoid LPC (SLT), which transmits all ATF to other solenoids.

Specialists recommend to monitor closely the ATF condition in the TL-80SN transmission. In case of rapid ATF contamination after the prior partial change, it is recommended to visit the repair shop for the torque converter repair, without waiting for the friction plate wearout, that may be especially harmful for the AA80E solenoids and the valve body. It is also advisable to replace the filter in due time, and check the pan.

The design of transmission components for all RWD Aisin transmissions is considered to be "invincible", having a large structural reserve. This transmission usually operates without serious problems throughout the car lifespan. However to avoid unnecessary repair costs, car owners have to monitor the ATF state, timely visit specialists for the torque converter repair, cleaning of solenoids and the valve body.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Cadillac	CTS	13-16	8 SP R/4WD	V6 3.6L
Hongqi	L7	12-16	8 SP RWD	V12 6.0L
LEXUS	GS	13-16	8 SP R/4WD	L4 2.0L V6 3.5L
LEXUS	GS	08-12	8 SP RWD	V8 4.6L
LEXUS	IS	07-16	8 SP R/4WD	L4 2.0L V6 3.5L V8 5.0L
LEXUS	LS	06-16	8 SP R/4WD	V8 4.6L
LEXUS	RC	14-16	8 SP RWD	L4 2.0L V6 3.5L V8 5.0L
Toyota	CROWN ROYAL	12-16	8 SP RWD	L4 2.0L V6 3.5L

How to repair this transmission (Videos)

Lexus AA80E (Aisin TL-80SN)

TAAT Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TAAT automatic gearbox was released in 1991 by Saturn LLC. This type of gearbox was mainly used in 1991-UP Saturn S-Series. In terms of design TAAT is a parallel shaft FWD unit with the drive gear. TAAT has 4 forward gears and 1 reverse gear by means of multidisc clutches, 4-element torque converter with a lock-up clutch, 1-st sprag-type clutch, and a tooth clutch activated by a servo unit.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		6,2	4,2-5,2	Dexron VI

Technical issues and repair guidelines

One of the main peculiarities of this transmission in comparison with common automatic gearboxes lies in the electronic control. This gearbox uses 5 solenoids together with the transmission control module and its sensors to control shift timing, shift feel, and give on board diagnostics.

Repair specialists say that the valve body is the most problematic component in TAAT. Delays, slippages, kicks or lack of Reverse during gear-shifting are likely to be caused by valve body issues. However, there are several other sources of a Reverse problem:

1. Delay or no Reverse may be caused by the loose-fitting main shaft nut

2. Malfunctioning car speed sensor may also lead to no-Reverse condition.

3. Wrong adjustment of the pattern select switch

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Saturn	S-SERIES	95-03	4 SP FWD	L4 1.9L

How to repair this transmission (Videos)

Valve Body Removal 1of 2

Valve Body Removal 2 of 2

Solenoid Testing & Replacing

DIY timing chain kit installation

SWRA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

HONDA SWRA / SWSA / SLTA / SLSA / SYEA / SYFA / SFBA / SFCA

The CVT Honda Multimatic SWRA / SWSA had been installed on right hand drive cars Honda Fit of the first generation (produced from 2001 till 2007) for the domestic market of Japan. It should be pointed out that Honda Fit cars for the American market were equipped not with CVTs, but with common automatic transmissions. Therefore, transmissions for Japanese and American models of Honda Fit are not interchangeable.SWRA is a continuously variable transmission produced by Honda. This transmission is used in some Honda cars (Civic, Jazz, Logo).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		5,9	2,5	Honda Multi Matic Fluid

CVTs SWRA / SWSA differ from each other not by engines (with which they operated), but by the purpose of CVT model (for FWD or AWD). In other words, Honda Fit cars with L13A and L15A engines were equipped with the same transmission SWRA / SWSA, but there was an important difference:

- SWRA – 2WD

- SWSA – 4WD

As the right hand drive Honda Fit of the first generation (produced from 2001 till 2007 ) served as a basis for other cars («Honda Airwave», «Honda Mobilio», «Honda Mobilio Spike»), then CVTs for these cars were slightly upgraded (the main difference lied in the housing mounting). These CVTs received new model names:

· Honda Airwave (from 2005 to 2007) 2WD – SLSA

· Honda Airwave (from 2005 to 2007) 4WD — SLTA

· Honda Mobilio/Mobilio (from 2002 to 2005) 2WD — SYEA

· Honda Mobilio/Mobilio (from 2002 to 2005) 4WD — SYFA

· Honda Mobilio Spike (from 2002 to 2005) 2WD — SFBA

· Honda Mobilio Spike (from 2002 to 2005) FWD – SFCA

· Honda Fit Aria / Honda City (from 2002 to 2009) 2WD — SERA

In fact all these car models were equipped with the same CVT. Transmissions differed only in the drive mechanism (FWD or AWD) and in holders for the CVT case. All other components of these CVTs are absolutely identical. Therefore, these CVTs may become interchangeable with the help of several minor modifications. Modifications usually consist in replacement of holders and some sensors.

According to Honda’s manual, SWRA / SWSA transmissions require ATF change вариатора (CVT) every 45 thousand kilometers. When the car operates in harsh conditions ATF should be changed after 22,5 thousand kilometers.

Harsh conditions usually include:

1.Frequent and short drives - no more than 8 km in the summer time or 16 km in the cold season (at negative air temperatures).

2. Operations under conditions of high temperatures (above +32 °C).

3. Long engine operation at idle speed, driving with frequent stops in traffic jams. Towing of the trailer or running on mountainous terrain.

4.Driving on dirty, dusty roads or on the roads which are subjected to treatment with anti-icing compound.

Honda Fit cars of the first generation equipped with CVTs SWRA / SWSA often face problems with the CVT mount, which tears after the car mileage reaches 50-60 thousand kilometers. Symptoms of this problem include the following: increased vibration, kicks at starting from rest/braking. Visual inspection helps to detect this problem. The mount is oil-filled, therefore transmission specialists recommend using original spare parts.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	CITY	00-12	CVT FWD	L4 1.3L 1.5L

How to repair this transmission (Videos)

Honda Civic CVT Transaxle Operation

RE4R03A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission RE4R03A ( RL4R01А/JR403E, RG4R01А) for engines with the capacity from 2 up to 3-liters was produced by Jatco in 1988 for the off-road vehicle Patrol. This transmission made a good impression and after some adjustments in 1999, it became widely used for RWD Nissan models. This gearbox found application on sport cars 300ZX and on Infiniti Q45 with V8 engines.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD		8,7	4	Dexron III

Technical issues and repair guidelines

This transmission is quite reliable as all rear-driven Nissan vehicles. In terms of design, this transmission is similar to RE4R01B\A and R4A-EL produced by Mazda. Repair parts for this gearbox are ordered in very rare cases. Therefore, in most cases owners of cars equipped with this transmission prefer to replace it with a new or used unit, rather then to spare time and money on its repair.

Typical problems of this transmission are similar to problems of the RE4R01A\B transmission. In most cases, repair specialists order the repair kit of gaskets and seals when they have to deal with this transmission. Sometimes, it is required to replace bushings on cars operating under severe conditions. In rare cases, it is necessary to change one of one-way clutches or set of solenoids, which get cleaned more often than replaced. Not complicated repair procedures for this reliable transmission can add several years to its service life.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dongfeng	RUIQI	08-16	4 SP R/4WD	L4 2.5L
Hyundai	PORTER	03-16	4 SP RWD	L4 2.5L
KIA	BONGO TRUCK	04-16	4 SP RWD	L4 2.5L 2.9L
Nissan/Datsun	300ZX	90-97	4 SP RWD	V6 3.0L
Nissan/Datsun	CARAVAN	12-16	4 SP R/4WD	L4 2.5L
Nissan/Datsun	CIVILIAN	00-16	4 SP RWD	L4 3.0L L6 4.2L 4.5L
Nissan/Datsun	FAIRLADY Z	0	4 SP RWD	V6 3.0L
Nissan/Datsun	FRONTIER	99-15	4 SP R/4WD	L4 3.0L 3.2L
Nissan/Datsun	HARDBODY	00-08	4 SP R/4WD	L4 2.4L
Nissan/Datsun	PALADIN	03-16	4 SP 4WD	V6 3.3L
Nissan/Datsun	PATROL	00-14	4 SP RWD	L4 3.0L L6 4.5L
Nissan/Datsun	SAFARI	97-16	4 SP 4WD	L4 3.0L L6 4.2L 4.5L 4.8L
Nissan/Datsun	TERRANO/REGULUS	03-06	4 SP R/4WD	L4 3.0L

How to repair this transmission (Videos)

RE4R03A Transmission Rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

RE4F03A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearbox RL4F03A / V RE4F03A / B was designed by Jatco in 1990 for FWD Nissan Primera with the engine capacity up to 2 liters. This transmission replaced the previous version RL4F02A with the hydraulic control.

In 1994, another update was made, and a new modification was released in 2000 under the name RE4F03B. The RE4F03A unit turned out to be very popular in accordance with the ratio price / reliability. After 2000, this transmission has been actively installed on the entire range of Nissan vehicles. Now this range of automatic gear shifting units is used for many models of Nissan cars all over the world.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD	240	8,2	3,5	AT-Matic D Fluid

Technical issues and repair guidelines

During each overhaul of this transmission, repair specialists replace the kit of gaskets and seals, which should be changed after a long-time operation to prevent the damage of the rubber elements. But the main repair procedure consists of replacement of rings, because their wearout may have a negative impact on the oil pressure in clutch packages. In most cases, repair procedures lie in cleaning and reassembly of the valve body, replacement of gaskets, spare parts, springs (of shock absorber), and the torque converter repair. Every second repair includes replacement of the solenoids block The issue with worn-out solenoids may lead to fluid shortages in clutch packages and result in slipping of friction clutches, oil burning and later burning of all frictions.

Hard parts of this transmission are very reliable. This gearbox may be considered invincible except for oil leakages from the pump seal (occur after 150 thousand kilometers), which usually says about the wear-out of torque converter spare parts and the pump bushing. It is recommended to change the fluid not according to its period of operation, but according to its transparency.

When this transmission unit in old cars is exposed to "oil starvation", then it may lead the following malfunctions ( in the following order):

- Reverse drum with the piston, wear-out of the surface by the brake band.

- High clutch drum. The shaft cranks, different types of wear-out of the shaft surface and drum. Reverse friction elements are prone to burning

If the fluid state in monitored and solenoids are timely replaced, then this transmission unit will operate properly for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Infiniti	G20	94-99	4 SP FWD	L4 2.0L
Nissan/Datsun	AD VAN	06-16	4 SP F/4WD	L4 1.2L 1.5L 1.6L 1.8L
Nissan/Datsun	ALMERA/ALMERA TINO	00-06	4 SP FWD	L4 1.8L
Nissan/Datsun	BLUEBIRD SYLPHY	06-16	4 SP FWD	L4 1.6L
Nissan/Datsun	CUBE/CUBE CUBIC	00-09	4 SP FWD	L4 1.3L 1.4L 1.5L
Nissan/Datsun	LATIO	07-12	4 SP FWD	L4 1.6L 1.8L
Nissan/Datsun	MARCH	06-16	4 SP FWD	L3 1.2L L4 1.5L 1.6L
Nissan/Datsun	MAXIMA	01-12	4 SP FWD	V6 3.0L
Nissan/Datsun	MICRA	03-12	4 SP FWD	L3 1.2L L4 1.2L 1.4L 1.6L
Nissan/Datsun	NOTE	05-13	4 SP FWD	L4 1.5L 1.6L
Nissan/Datsun	NOTE	06-16	4 SP FWD	L4 1.6L 1.8L
Nissan/Datsun	NV200	09-16	4 SP FWD	L4 1.5L 1.6L
Nissan/Datsun	PULSAR	00-06	4 SP F/4WD	L4 1.8L 2.0L
Nissan/Datsun	SENTRA	93-12	4 SP FWD	L4 1.3L 1.6L 1.8L 2.0L 2.5L
Nissan/Datsun	SUNNY	97-16	4 SP FWD	L4 1.5L 1.6L
Nissan/Datsun	TEANA	06-08	4 SP FWD	L4 2.0L
Nissan/Datsun	TIIDA	05-16	4 SP FWD	L4 1.6L 1.8L
Nissan/Datsun	WINGROAD	05-16	4 SP F/4WD	L4 1.5L
Samsung	SM3	02-13	4 SP FWD	L4 1.5L 1.6L
Samsung	SM5	00-09	4 SP FWD	L4 1.8L 2.0L V6 2.0L
Venucia	D50	12-16	4 SP FWD	L4 1.6L
Venucia	R30	16	4 SP FWD	L3 1.2L
Venucia	R50	12-16	4 SP FWD	L4 1.6L 2.0L

How to repair this transmission (Videos)

RE4F03A Nissan

RE4FO3B Teardown

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual RE4F03A
pdf	www.at-manuals.com	Service manual RE4F03A
web	www.at-manuals.com	Line pressure specifications RE4F03A

RL4F02A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission RL4F02A and and its modification RE4F02A (produced by Jatco) found application on FWD Nissan models with the engine capacity of approximately 2.0 liters. The RL modification is intended for lower torque from engines 1.6-2.4 lit, while the RE modification had been installed on 3.0 Maxima until 1994. This transmission had been used on Maxima and Pulsar for 5 years, then it was replaced by more sophisticated and low-priced version- RE4F04A and RE4F03A for engines with the capacity of up to 2-lit.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	260	6		Nissan AT-Matic D Fluid

Technical issues and repair guidelines

This transmission is quite reliable, but when it comes to the repair of this transmission is can be quite expensive. Thus, many car owners prefer to replace this gearbox by the used one. The problem of “old” RL4F02A transmissions as in all Nissan gearboxes lies in the electronic control elements. The torque converter lock-up solenoid operates quite intensively and gets out of service very early. It was modified several times.The rest of solenoids should also be changed before they stop operating properly, because it leads to the oil starvation, cranking of bushings, deterioration of drums, planetary gears and pump.

But usually issues are related to general ageing of rubber gaskets and wear-out of friction components, which contaminate valves of the valve body and solenoids, prevent springs from moving valve cores. All this results in such common issues as jolts and stoppages. The wear-out of friction elements initially affects the torque converter lock-up mechanism, then worn-out clutches start slipping at some gears and the car ceases moving uphill. Generally, this transmission is quite reliable and has a high operational reserve. After the reassembly and cleaning, this gearbox can operate on the snow and in off-road conditions for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Nissan/Datsun	AXXESS	90	4 SP FWD	L4 2.4L
Nissan/Datsun	PULSAR	88-90	4 SP FWD	L4 1.8L

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme RL4F02A

RL3F01A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

RL3F01A is one of the first 3-speed automatic transmissions Jatco (RN3F01A) had been installed года on some rear wheel drive small cars of Nissan (PULSAR, SENTRA, STANZA) since 1982 until 1989. This is the first transmission with introduced forced torque converter lock-up. The family of 4-speed automatic transmissions RL4F01A \ RE4F02A was released simultaneously with RL3F01A and was very popular.RL3F01A is the successor of 3-speed rear wheel drive automatic transmission 3N71B (later modified in L4N71B, JR401E).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD	150	6,1	2,8	AT-Matic D Fluid

Technical issues and repair guidelines

For the overhaul of this automatic transmission (which takes place very rarely) transmission specialists order the following:

-the kit of friction clutches or clutches Forward (when ordering separate parts).

Metal filter which is usually cleaned and washed. Following the above mentioned recommendations may be enough (if the oil is not burnt) to prolong the service lifespan of this transmission for several years.

- repair kit of gaskets and seals (by the time of the overhaul all gaskets are very old, rubber gets damaged and seals start leaking because of long time in service.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Nissan/Datsun	PULSAR	83-90	3 SP FWD	L4 1.5L 1.6L

How to repair this transmission (Videos)

Transmission valve body assembly

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme RL3F01A

RE0F21A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The infinitely variable speed transmission RE0F21A (JF012E) was developed by Jatco in 1999 on the basis of RE0F06A as a CVT solution of the “extra-lite” class with a minimum torque. For several years, this CVT had been installed on Nissan Cube with the engine capacity equal to 1300 cm3. It was also tested on Italian Fiat (DLTC46FHJ1AA) as an automatic alternative for Punto, Albea, Uno and others, which were in production until recent years. In terms of design, this CVT is similar to RE0F10A, JF011E, RE0F06A.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	130	5	2,5	CVT Fluid NS-1

Technical issues and repair guidelines

Repair procedures for this transmission usually involve timely fluid change and sometimes filter replacement. Sometimes it comes to replacement of the belt which fits to some related CVTs from Honda and Mitsubishi. In rare cases, burnt Forward and Reverse frictions get replaced. Frictions get burnt because of worn-out rings and gaskets (Repair kit of gaskets and seals). Burnt fluid damages rubber seals, therefore experts recommend to replace all rings of this CVT RE0F21A in the course of overhaul. The major part of spare parts for repair of this CVT is bought on the market of used spare parts, and repair of this CVT is less frequent than replacement for "used" CVTs.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Nissan/Datsun	CUBE	00-02	CVT F/4WD	L4 1.3L

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme RE0F21A

R4A51 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission R4A51 (V4A51) was used since 1997 for RWD Montero models with engine capacity from 3-liters. In a couple of years, the new 5-speed R5A51 (2000-2006) and AWD V5A51 versions were launched. This family of automatic transmissions competed with RWD AW30-40LE by Aisin.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		9,6	4	SP III

Technical issues and repair guidelines

Commonly, planned overhaul of these transmissions consists in cleaning of the valve body, repair of the torque converter and ATF change. These measures are assumed to be enough for another 2-3 years of proper operation, if gaskets are intact and the oil pressure in packages conforms to requirements.The reassembly of this transmission usually includes not only the repair kit of gaskets and seals, but also the kit of frictions and the kit of steel discs. A rather long-lived clutch of the torque converter lock-up may be exposed to wearout. In some cases, it may operate until 200 thousand kilometers. The untimely replacement of the friction component results in beatings, damage of the pump seal, and later breakdown of the pump bushing.

Typical problems of R4A51 (V4A51)

Filters are clogged with wear-out products and there are two modifications of filters for transmissions applied in RWD cars. The planetary gear (O.D.) rapidly gets out of order under the condition of extreme and frequent loads close to the torque limit. In the process of reassembly, the valve body is washed and may operate properly till the end of the car lifespan. During the first overhaul, specialists replace some solenoids that operate very intensively, namely EPC solenoid and the solenoid of the clutch lock of the V5A51 torque converter operating in the dirtiest and hottest fluid. Input shaft sensors get out of order because of old age, oil contamination by steel shavings, and overheating It is recommended to replace all frictions and the brake band in case of a long-term operation with burnt fluid.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mitsubishi	MONTERO XLS/MONTERO SPORT	01-04	4 SP R/4WD	V6 3.0L 3.5L

How to repair this transmission (Videos)

F4A51 Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual R4A51
web	www.at-manuals.com	Scheme R4A51
pdf	drive.google.com	Repair manual R4A51, V4A51, V5A51
pdf	Sonnax	Valve Body Layout V5A51

MHTA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

HONDA MHTA / SPSA / SMLA / SBLA / STYA / SZCA

MHTA / SPSA / SMLA / SBLA / STYA / SZCA CVT models were developed by Honda for usage in their hybrid vehicles. These CVTs were installed on Honda cars for the domestic Japanese market and for markets of the USA and Europe.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		5,8	3,5	Honda Genuine CVT

■MHTA was used on HONDA INSIGHT from 2001 to 2006 with the engine L4 1.3L

■SPSA was used on HONDA CIVIC HYBRID from 2006 to 2012 with the engine L4 1.3L

■SMLA was used on HONDA CIVIC HYBRID from 2006 to 2012 with the engine L4 1.7L

■SZCA was used on HONDA CIVIC HYBRID from 2003 to 2005 with the engine L4 1.3L

■SZCA was used on HONDA FIT HYBRID from 2003 to 2008 with the engine L4 1.3L

■SBLA was used on HONDA INSIGHT from 2010 to 2014 with the engine L4 1.3L

■STYA was used on HONDA CR-Z from 2011 to 2017 with the engine L4 1.5L

These CVTs are very similar in design and have many common internal parts that greatly facilitates their repair.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	INSIGHT	01-06	CVT FWD	L3 1.0L

MB1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 3-speed automatic transmission Renault MB1 was released in the early 1980-s. This transmission was used for many Renault vehicles, such as Renault 5, 9, 11, 19, Clio and Twingo.

This transmission has 3 forward gears and 1 reverse gear which are combined in the uniform unit with the drive gear and electronically-controlled differential. The oil pump is activated by the engine shaft via the torque converter and transmits the oil under pressure to the gearbox, where it is used as a lubricant and for controlling actuators.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD	150	5,1	3,5	Dexron III

Technical issues and repair guidelines

The most widespread malfunctions of MB1:

• Gear fails to switch on. Any malfunction of solenoid-controlled valves of the hydraulic distributor switches the automatic transmission into emergency mode.

• Oil leakages. In many cases car owners are bothered by ATF leakages. Usually the oil leaks at the junction of the motor and the automatic transmission.

• Critical breakdowns. Low oil level and the pressure loss caused by the valve breakdown lead to burn-out of friction plates.

• Shifting failure. A poor valve body breaks before reaching 100 thousand kilometers. This problem has the following symptoms: jerks, kicks and failure of some gears.

According to transmission repair specialists the resource of this transmission is equal to 100 - 150 thousand kilometers, but it is very unlikely that this transmission will cover such distance without any repairs.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Renault	R19	00-01	3 SP FWD	L4 1.4L

How to repair this transmission (Videos)

How to make the maintenance

K310 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

TOYOTA K310 / K310F / K311 / K311F / K312 / 313

In 2006, Aisin started production ofCVTs of the K310/K311 series. From Toyota’s perspective, this gearbox was a great option for 1.5-1.8 liter gasoline engines. In November 2008, Toyota cars (Toyota Avensis and Toyota Verso), equipped with the K311, appeared on the European market. In 2012, Aisin improved these CVTs (primary from the point of view of fuel economy) and released a new CVT of this family named as K312/K313.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	175	7	4	Aisin CVTF7004, Toyota 08886-02105

Earlier, each Toyota car model was equipped with a particular CVT from the beginning till the end of its production cycle. With regard to CVTs of “300” series the situation changed. In fact, the K310 CVT model was manufactured until 2015. However in 2012, more modern CVT K313 replaced K310 on some car models (for domestic market). In 2015, Toyota models (Toyota Avensis and Toyota Verso) for the European market were equipped with the K313 CVT instead of K311. The same changes concerned Toyota Corolla.

Typical problems of These CVTs are similar to issues which occur in the “200” series (ATF contamination, overheating, damage of bearings, seal leakages).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Subaru	TREZIA	10-16	CVT F/4WD	L4 1.5L
Toyota	ALLION	07-16	CVT FWD	L4 1.5L
Toyota	AURIS	12-16	CVT 4WD	L4 1.5L
Toyota	COROLLA	12-16	CVT 4WD	L4 1.5L
Toyota	IST	07-10	CVT F/4WD	L4 1.8L
Toyota	PORTE	12-16	CVT F/4WD	L4 1.5L
Toyota	PREMIO	07-16	CVT FWD	L4 1.5L
Toyota	RACTIS	10-16	CVT F/4WD	L4 1.5L
Toyota	RUMION	07-15	CVT FWD	L4 1.5L
Toyota	WISH	09-13	CVT FWD	L4 1.8L

How to repair this transmission (Videos)

Component and Operation CVT K311 K111

K310-K311 CVT Altis Repair

RE7R01A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 7-speed automatic transmission RE7R01A with longitudinal positioning for rear drive (according to Jatco classification - JR710E) was produced by Jatco. It was unitized since 2009 with all engines of Infinity and Nissan from V6 3.0 liters up to V8 5.6 liters (RE7R01B \ JR711E). In addition to Infinity, this transmission is installed on the following SUVs: Nissan Fuga, Pathfinder, Patrol etc.The modification named RE7R01B (Patrol/ QX56/ M56) is intended for high torque models (up to 600 Nm), in contrast with 400 Nm for the RE7R01A.RE7R01A model is a worthy competitor on price and fuel economy with transmissions produced by Aisin and ZF. There are possibilities for the mode of fast and economical car acceleration with switched on "slippery" of the torque converter clutch.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	AT	RWD/AWD	400	9,2	5	NISSAN Matic S

Technical issues and repair guidelines

Like in all RWD automatic transmissions of Jatco, the design of RE7R01A elements implies a very long resource for this gearbox under the condition of preventing operation with contaminated fluid, which leads to the chain reaction: contaminated oil results in worn-out teflon rings, clogged valve body, worn-out solenoids leading to oil starvation of frictions.

It is common to replace torque converter spare parts in the course of overhaul of this transmission. Traditionally, the JR710 reassembly includes the repair kit of gaskets and seals. All rings, gaskets, and seals get replaced. The brake pack В3 (2-3-4-6) is the first to sense reduced oil pressure. Frictions with steel discs get burnt. The pack of С1 (Input) frictions is the second to get burnt. In this case, it is required to replace the whole set of frictions. Regular cleaning of the valve body and repair of the torque converter are performed together with replacement of the hydraulic clutch frictions. Problems in the RE7R01 electrical part are related to the valve body and the control unit.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Infiniti	EX/QX50	08-16	7 SP R/4WD	V6 2.5L 3.5L 3.7L
Infiniti	EX35	11	7 SP R/4WD	V6 3.5L
Infiniti	FX	08-16	7 SP R/4WD	V6 3.0L 3.5L 3.7L
Infiniti	FX35	09-12	7 SP R/4WD	V6 3.5L
Infiniti	G	08-15	7 SP R/4WD	V6 2.5L 3.7L
Infiniti	G/Q60	08-16	7 SP R/4WD	V6 2.5L 3.7L
Infiniti	G25	10-12	7 SP R/4WD	V6 2.5L
Infiniti	G37	09-12	7 SP R/4WD	V6 3.7L
Infiniti	M/Q70	10-16	7 SP R/4WD	V6 2.5L 3.5L 3.7L
Infiniti	M35	9	7 SP R/4WD	V6 3.5L
Infiniti	M37	09-12	7 SP R/4WD	V6 3.7L
Infiniti	Q50	13-16	7 SP R/4WD	L4 2.0L V6 3.0L 3.7L
Infiniti	Q60	16	7 SP R/4WD	V6 3.0L
Infiniti	Q70	16	7 SP R/4WD	V6 3.0L
Infiniti	Q70L	12-16	7 SP R/4WD	V6 2.5L 3.0L 3.7L
Renault	1T PICKUP	16	7 SP R/4WD	V6 4.0L

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Solenoid/component application chart
web	www.at-manuals.com	Transmission breakdown illustration

JR405E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearboxes RC4A-EL for RWD and AWD vehicles with engines 1.6 – 3 lit. were designed in 1999 for Mazda and Nissan on a Japanese market. It was frequently installed on RWD models Isuzu and Suzuki.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD	300	8,7		AT-Matic J

Technical issues and repair guidelines

Old cars with the mileage higher than 150 thousand kilometers commonly get some linehaul external filter cut in the oil cooling line by specialists in order to refine quickly contaminating oil and protect solenoids and the valve body. After travelling more than 200 thousand kilometers, it is necessary to repair the torque converter for saving the pump and the bushing. This transmission is quite rare and reliable unit, for which it is necessary to change fluid and monitor conditions of gaskets and seals on a timely basis. It is a common case to order solenoids and sometimes repair kits of gaskets and seals for major repairs of this transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	COLORADO	04-11	4 SP R/4WD	L4 2.4L 2.8L 3.0L
Isuzu	ADVENTURE MASTER	03-07	4 SP RWD	L4 3.0L
Isuzu	D-MAX	02-13	4 SP RWD	L4 3.0L
Isuzu	GRAND ADVENTURE	00-03	4 SP RWD	L4 3.0L
Isuzu	MU-X	13-16	4 SP 4WD	L4 3.0L
Isuzu	SPACE CAB	00-03	4 SP RWD	L4 3.0L
Mazda	BONGO	99-16	4 SP R/4WD	L4 1.8L 2.0L
Santana	300/350	05-08	4 SP RWD	L4 1.6L
Suzuki	VITARA	00-05	4 SP RWD	L4 1.6L

How to repair this transmission (Videos)

JR405E Transmission Rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	ukrtrans.biz	Repair manual RC4AEL
pdf	automaticchoice.com	Scheme JR405E

RE4R01A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission RE4R01A\B (medium-duty class) RL4R01A (JR402A) found application in RWD and 4WD vehicles (Pathfinder, PickUp X-Terra) with engine capacity from 2 up to 4.5 liters. This gearbox rarely fails and traditionally is considered to be an “invincible” RWD transmission. The RE4R01A\B transmission was produced by Jatco-Nissan in 1987. The design of this transmission was updated several times and as a result it got an electronic control unit (and letter Е in its name instead of hydraulic "L" - RL4R01A). All these modifications have the same structural design and differ in only in some spare parts.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD		6,9	3,1	Matic-D

Technical issues and repair guidelines

The overhaul of this transmission is commonly performed after running 250-400 thousand kilometers. Well-timed and correct reassembly of this system adds a significant resource to the whole unit. In the course of reassembly, it is required to clean the valve body and fix the worn-out torque converter. Another measure is to check and replace spare parts - gaskets, rings, friction components.The package High typically is the first to get burnt. The kit of gaskets and seals (Overhaul kit) is a common order for the overhaul procedure.

Each repair of the "old" RE4R01A involves replacement of the following components:

- Brake band Overdrive 37 mm (Low-Reverse)

- Set of 4 solenoids (together with replacement of the torque converter spare parts).

The first hard part to exhaust its solid resource is the assembled planetary gear (Rear-Front) and burning High package. Worn solenoids cause insufficient oil pressure almost unnoticeable while driving, but results in wearout of all bushings and burning of friction components.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	EVEREST	03-15	4 SP R/4WD	L4 2.5L
Infiniti	J30	92-97	4 SP RWD	V6 3.0L
Infiniti	M30	90-92	4 SP RWD	V6 3.0L
Infiniti	QX4	97-03	4 SP 4WD	V6 3.3L 3.5L

How to repair this transmission (Videos)

RE4RO1A Teardown

RE4R03A Transmission Rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme RE4R01A

JF405E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed JF405E automatic transmission with the east-west mounting (its forerunner is JF402E) was produced by Jatco in 2000 for the mini cars of the Korean FWD family Hyundai-Kia-Daewoo. The JF405E is used on FWD cars Daewoo / Chevrolet, Kia and Hyundai with the engine capacity up to 1.1 liters. The most common models to be found in repair services are Daewoo Matiz and Kia Picanto.In terms of design, this automatic transmission is related to the 4-speed SR410 (SR412, SR413) designed by Jatco in 1998, on order of Suzuki for Wagon R, and then installed on Alto, therefore many spare parts are interchangeable.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		7,5	4	JWS 3314

Technical issues and repair guidelines

The most common repair procedure for this CVT is the transmission reassembly with replacement of gaskets and seals (Overhaul kit) which are different depending on years of production – before 2003 and after 2003.The most common order this transmission is a budgetary repair kit of gaskets and seals. A standard order on the transmission reassembly also includes the kit of friction components.

Suzuki repair lies in procedures preventing oil leakages, namely the pump seal replacement. This procedure should be accompanied by the pump bushing replacement. One more required measure is the torque converter repair, which has a worn-out locking mechanism, which causes vibrations, hub heating, and damage of the pump seal.

In many cases, owners of JF405E-equipped cars with dirty valve bodies just replace EPC solenoid . This solenoid operates more intensively than others, has no pre-filter from dirt in ATF and wears out earlier. Worn-out rings are usually replaced together with the abovementioned solenoid because leakages in these rings result in lower oil pressure in packages. Old JF405E usually have problems with planetary gears (front and rear).The main pressure solenoid (EPC) is the first to get out of order in the electrical part, then comes solenoid of the torque converter lock-up.

Generally, it’s a very reliable and long-serving transmission where the major part of overhauls lies in the replacement of solenoid, replacement of the valve body, rubbers, sealing rings from the repair kit. It is also required to change the friction lining of the torque converter, which is the "enemy" №1 to the cleanness of ATF and the valve body.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	SPARK	03-13	4 SP FWD	L3 0.8L 1.0L
Chevrolet/GM	SPARK	09-16	4 SP FWD	L4 1.0L
Daewoo	MATIZ	05-15	4 SP FWD	L3 0.8L L4 1.0L
Hyundai	ATOZ	98-14	4 SP FWD	L4 1.1L
Hyundai	SANTRO	00-07	4 SP FWD	L4 1.1L
KIA	MORNING	04-10	4 SP FWD	L4 1.0L 1.1L
KIA	PICANTO	06-09	4 SP FWD	L4 1.0L
KIA	VISTO	00-03	4 SP FWD	L3 0.8L
Maruti-Suzuki	A-STAR	10-14	4 SP FWD	L3 1.0L
Nissan/Datsun	MARCH	02-06	4 SP FWD	L4 1.0L
Opel / Vauxhall	AGILA	00-06	4 SP FWD	L4 1.0L
Suzuki	ALTO	04-14	4 SP F/4WD	L3 0.7L
Suzuki	CERVO	07-10	4 SP F/4WD	L3 0.7L
Suzuki	CULTUS	00-03	4 SP FWD	L4 1.3L
Suzuki	KEI	00-10	4 SP FWD	L3 0.7L
Suzuki	LAPIN	02-15	4 SP F/4WD	L3 0.7L
Suzuki	MR WAGON	02-11	4 SP F/4WD	L3 0.7L
Suzuki	PALETTE	08-11	4 SP F/4WD	L3 0.7L
Suzuki	WAGON R	00-12	4 SP F/4WD	L3 0.7L

How to repair this transmission (Videos)

J405E internals

Valve body repair JF405E

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme JF405E
web	autocats.ws	SCHEMATIC DIAGRAMS JF405E

JF404E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission JF404E of the class "mini" was produced by Jatco in 2000 for FWD vehicles with engine capacity from 1.3 up to 1.6 liters. The JF404E unit is usually installed on Nissan, Suzuki (Ignis and Wagon). This transmission was designed on the basis of SR410 (SR412) used in Suzuki Wagon R and JF405E for engines with a lower torque and related transmission of the "middle" class JF403E for engines up to 2.5 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	150	7,5	4	Matic Fluid D

Technical issues and repair guidelines

The valve body has two modifications. The first one has 6 solenoids and higher demand on the market. Solenoids are simple “on-off” electrovalves with a ball, they operate properly during the whole service life of the transmission, even if channels are worn-out by contaminated ATF. There is also a rare modification with the angled filter and 5 solenoids (the second type of the valve body).

Vulnerabilities and repair procedures

Soft spots of old JF404E transmissions are similar to vulnerabilities of JF405E units. But the main reasons for overhauls are related to overall contamination and aging of the transmission, the torque converter wear-out, accumulation of friction dust in the valve body, wear-out of friction elements. If a driver notices problems with the gearbox at the proper time, then the repair procedure involves the valve body cleaning, solenoids washing, torque converter repair. Usually implementation of these procedures adds several years to the service life of the transmission.

When dirty valves of the valve body operate for a long period of time, then wear-out of housing channels of the valve body leads to harmful ATF overflows and necessity to change the whole valve body or more often change of the whole transmission unit. Rare overhauls lie in the gearbox reassembly and replacement of the overhaul kit – repair kit of spare parts, consisting of teflon rings, gaskets, and seals. This transmission is very reliable, not complex in the repair. When monitoring fluid cleanness, preventing a smell of burning, then the transmission will operate for many years without serious problems.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	LASER	00-06	4 SP FWD	L4 1.5L
Isuzu	GEMINI	0	4 SP FWD	L4 1.5L 1.6L
Nissan/Datsun	ALMERA	00-06	4 SP FWD	L4 1.6L
Nissan/Datsun	NV	00-06	4 SP FWD	L4 1.5L 1.6L
Nissan/Datsun	PULSAR	00-12	4 SP FWD	L4 1.5L 1.6L 2.0L
Nissan/Datsun	RASHEEN	00-01	4 SP F/4WD	L4 1.5L 1.8L
Nissan/Datsun	SENTRA	00-09	4 SP FWD	L4 1.3L 1.6L 1.8L
Nissan/Datsun	SUNNY	00-04	4 SP FWD	L4 1.3L 1.5L 1.6L 1.8L
Nissan/Datsun	TIIDA	12-16	4 SP FWD	L4 1.6L
Seat	AROSA	00-04	4 SP FWD	L4 1.4L
Seat	CORDOBA	02-07	4 SP FWD	L4 1.4L
Seat	IBIZA	01-08	4 SP FWD	L4 1.4L
Skoda	FABIA	01-08	4 SP FWD	L4 1.4L
Suzuki	IGNIS	04-07	4 SP FWD	L4 1.5L
Suzuki	WAGON R	00-04	4 SP FWD	L4 1.3L
Volkswagen	LUPO	00-05	4 SP FWD	L4 1.4L
Volkswagen	POLO	01-07	4 SP FWD	L4 1.4L

Instruction manuals and useful links

Link type	Source	Description
pdf	ukrtrans.biz	Technical manual JF404E
pdf	alltranz.co	Scheme JF404E

RE4F04A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission RE4F04A was designed by Jatco in 1993 for 3 liter Maxima using the experience of the JF403E gearbox which was created in 1990 for Isuzu. Later this transmission was installed on other popular Nissan and Infinity models with engine capacity up to 3 liters. At the same time, another modification RE4F03A was released for lower torque from engines with the capacity up to two liters. This family of 4-speed automatic transmissions is used on FWD vehicles with engines from 2 up to 3 liters. Experts call this gearbox as " the 04-th Nissan", which is considered to be Jatco's achievement in terms of reliability and price.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	290	9,5	4,5	Nissan Matic-D

Technical issues and repair guidelines

RE4F04A is the most popular Nissan gearbox in repair services, which is called "the 4-th Nissan" according to the professional slang.

Typical repair procedures for old automatic gearboxes RE4F04\ LJ4A-EL

In addition to the common set of repair parts for reassembly of the old RE4F04A, it is required to replace the friction lining of the torque converter lockup. When using a powerful engine, the torque converter of this transmission damages its clutch coupling. The lock-up mechanism, damaged till the glue layer, clogs the valve body and gives severe vibrations on the pump shaft, damaging both the pump seal and the pump itself. The first sign of the faulty torque converter is a leaking seal.

Repair of torque converter

In these Jatco transmissions, the brake band may be considered as the spare part of the first priority. The brake band is replaced together with change of frictions in the High package. All friction elements get replaced if the car comes in the repair service with burnt fluid. Many repair parts of the JF506E transmission can be used for repair of RE4F04A. Typical problem element of this transmission is the rear planetary gear. When driving for a long period of time with worn-out torque converter and leaking pump seal, you can face the problem of worn-out pump cover bushing. Another common component to be replaced is the set of solenoids in the RE4F04 unit. Solenoids operate under different load, pair of the most extensively operating solenoids is the first to exhaust its resource from the whole block, but they are replaced altogether. High Clutch and Forward Clutch get out of order in most cases.

In general, this transmission has a significant reserve, allowing drivers to use the potential of this transmission to the fullest. It gets out of order only when the pan already contains much of metal chips and shavings. Under the condition of well-timed torque converter repair and maintenance services, this transmission can serve for incredibly long periods of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	ESCAPE	12	4 SP F/4WD	L4 2.3L
GEO	STORM	90-93	4 SP FWD	L4 1.6L 1.8L
Isuzu	IMPULSE	90-92	4 SP FWD	L4 1.8L
Mazda	MPV (VAN)	00-02	4 SP F/4WD	L4 2.5L V6 2.9L
Nissan/Datsun	MAXIMA	00-02	4 SP FWD	V6 3.0L

How to repair this transmission (Videos)

RE4FO4A Teardown

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual RE4F04A
web	www.at-manuals.com	Stall test RE4F04A
web	Sonnax	RE4F04B Solenoid Identification

JF016E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In 2012, Jatco released the next generation of CVTs named as CVT8- JF016E to replace its best-selling JF011E. Firstly, Jatco tested CVT7-JF015E for classes "mini" and "micro" with engine capacity from 0.7 up to 1.6 liters. And when it became apparent that new features allow this gearboxes to be installed on vehicles with engines up to 1.8 liters, JF016E version was introduced for medium and premium class vehicles with engines up to 2.5 liters. Since 2014, this CVT entered production, and completely replaced its predecessor JF011E.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		8	4,5	CVT Fluid NS-3

Technical issues and repair guidelines

The valve body of the CVT8 unit has a reduced number of valves. The torque converter lock-up zone was expanded,allowing to improve acceleration and fuel saving characteristics, but on the other side the lock-up clutch wear-out leads to rapid contamination and necessity to repair the torque converter.

Repair procedures

During the first years after release of the series, Jatco engineers adjusted the TCM settings in such a way that they allowed loading of CVT components to the limit to attract potential buyers with enhanced acceleration dynamics. Therefore, the valve body replacement may occur during the warranty period. The design of JF016E components is very similar to the JF011E unit. Thus, it is expected that this CVT will be “invincible” on vehicles with engines up to 2.4 liters and that CVT on Nissan Murano with 3.5 liter engine will frequently appear in repair services.

During the first years of operation, repair specialists have to replace the oil filter-cartridge. This filter-cartridge is installed in the heat exchanger and maintains the "right" fluid level in the pan. Cone bearings are considered to be another vulnerable place in this CVT as in its predecessor. Bearings for the next JF017E modification were significantly improved. Problems may occur with the pump JF016E- 017E, which has fewer components in comparison with JF011, but operates as intensive as its predecessor. This CVT is also sensitive to contaminated and overheated transmission fluid.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	CITY EXPRESS	14-16	CVT FWD	L4 2.0L
Dongfeng	MX6	15-16	CVT FWD	L4 2.0L
Dongfeng	YUMSUN	15-16	CVT FWD	L4 2.0L 2.5L
Mitsubishi	DELICA D:5	14-16	CVT F/4WD	L4 2.0L 2.4L
Mitsubishi	LANCER	13	CVT FWD	L4 1.8L 2.0L 2.4L
Mitsubishi	OUTLANDER	14-16	CVT F/4WD	L4 2.0L 2.4L
Mitsubishi	RVR	12-16	CVT F/4WD	L4 1.6L 1.8L 2.0L
Nissan/Datsun	ALTIMA	12-16	CVT FWD	L4 2.5L
Nissan/Datsun	ELGRAND	13-16	CVT F/4WD	L4 2.5L
Nissan/Datsun	JUKE	13-16	CVT F/4WD	L4 1.6L
Nissan/Datsun	MURANO	15-16	CVT 4WD	L4 2.5L
Nissan/Datsun	NV200	13-16	CVT FWD	L4 2.0L
Nissan/Datsun	PATHFINDER	13-16	CVT F/4WD	L4 2.5L
Nissan/Datsun	PULSAR	14-16	CVT FWD	L4 1.2L 1.5L
Nissan/Datsun	QASHQAI	13-16	CVT F/4WD	L3 1.2L L4 1.2L 2.0L
Nissan/Datsun	ROGUE	13-16	CVT F/4WD	L4 2.0L 2.5L
Nissan/Datsun	SYLPHY	12-16	CVT FWD	L4 1.6L 2.0L
Nissan/Datsun	TEANA	12-16	CVT F/4WD	L4 2.0L 2.5L V6 2.5L
Nissan/Datsun	TEANA VIP	13-16	CVT FWD	L4 2.0L 2.5L
Nissan/Datsun	TIIDA	13-16	CVT FWD	L4 1.6L
Renault	CAPTUR	16	CVT F/4WD	L4 2.0L
Renault	CLIO	12-13	CVT FWD	L4 1.5L
Renault	FLUENCE	14-16	CVT FWD	L4 2.0L
Renault	KADJAR	16	CVT F/4WD	L4 1.2L 2.0L
Renault	LAGUNA	16	CVT FWD	L4 1.2L 1.3L 1.6L 2.0L
Samsung	LAGUNA	16	CVT FWD	L4 2.0L
Samsung	QM5	16	CVT FWD	L4 1.6L
Samsung	SM3	16	CVT FWD	L4 2.0L
Suzuki	SX4 S-CROSS	13-16	CVT F/4WD	L4 1.6L
Suzuki	VITARA	15-16	CVT FWD	L4 1.4L
Venucia	T70	15-16	CVT FWD	L4 2.0L

Instruction manuals and useful links

Link type	Source	Description
pdf	automaticchoice.com	Scheme JF016E

JF015E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In 2010, Jatco produced the next generation of CVTs named as CVT7-JF015 (RE0F11A) to replace its predecessor JF011E. In terms of design, this CVT is significantly distinct from JF011E. The JF015 unit also has the torque converter (TC), that reduces the load on shafts, planetary gear for the back run, but the primary peculiarity lies in two forward motion speeds and 3 friction clutch packages: Direct №1(Low), - №2(High) and Reverse.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD		8	4,5	CVT Fluid NS-2

Technical issues and repair guidelines

This construction may be regarded as a mixture of CVT and 2-speed transmission, that allows reducing cones by exceeding the gear ratio by means of two forward gears. As JF015E, this transmission has been used on Suzuki Swift, Splash, Alto, and on some Mitsubishi cars since 2012.

Common problems of the JF015 unit are similar to issues of its predecessor JF011. In most cases, problems occur after significant mileage and may be characterized as "spare parts wear-out". The most urgent repair procedure for CVTs is the replacement of teflon rings, which are replaced together with the input shaft repair and replacement of frictions, replacement of bearings, or change of the belt caused by the exploitation with worn-out rings which rapidly decreases the resource of all these parts. A common issue of JF015 is the input shaft bearing failure. The main shaft is considered to be a soft spot leading to the abovementioned problem.

This transmission is sensitive to contaminated and cold ATF. Frequent usage in winter time with oil temperature below +60 results in slipping and damage of the belt and cones. The belt is a common spare part for all “ageing” Jatco units. Well-timed replacement of the belt having still operating protector helps to prolong the resource of cones, which are considered to be the most important and high-priced unit of the CVT design.

Another frequently replaced component of JF015E is the damaged sun gear. The wear-out of solenoids occurs because of ATF contamination caused by the wear-out of rings and seals, forcing the pump to transmit increased ATF volume in order to make up for shortage of pressure on clutches. Therefore, solenoids are replaced together with all gaskets and rings. The issue of input and output shaft bearings is expected to occur when driving with a slipping belt.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	SPARK	12-16	CVT FWD	L3 1.0L L4 1.0L 1.2L 1.4L
Citroen	RVR	12	CVT FWD	L4 1.6L
Maruti-Suzuki	SWIFT	14-16	CVT FWD	L4 1.2L
Mazda	CAROL	15-16	CVT F/4WD	L3 0.7L
Mazda	FLAIR	16	CVT F/4WD	L3 0.7L
Mazda	FLAIR CROSSOVER	14-16	CVT F/4WD	L3 0.7L
Mazda	FLAIRWAGON	12-16	CVT F/4WD	L3 0.7L
Mitsubishi	ATTRAGE	13-16	CVT FWD	L3 1.0L 1.2L
Mitsubishi	EK SPACE	14-16	CVT F/4WD	L3 0.7L
Mitsubishi	EK WAGON	13-16	CVT F/4WD	L3 0.7L
Mitsubishi	FORTIS	14-16	CVT FWD	L4 1.8L
Mitsubishi	I	12-13	CVT FWD	L3 0.7L
Mitsubishi	LANCER	13	CVT FWD	L4 1.5L 1.6L
Mitsubishi	MIRAGE	12-16	CVT FWD	L3 1.0L 1.1L 1.2L L4 1.3L
Mitsubishi	RVR	13-16	CVT F/4WD	L3 1.2L L4 1.6L 1.8L
Mitsubishi	TOPPO	13	CVT FWD	L3 0.7L

How to repair this transmission (Videos)

Teardown and Failure Analysis - Part 1

Teardown and Failure Analysis -Part 2

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout JF015E (RE0F11A)
pdf	Sonnax	Vacuum Test Guide JF015E

JF010E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The constantly variable transmission (CVT) RE0F09A/B (also named as JF010E – according to Jatco classification) is designed on the basis of famous RE0F06A, but for higher torque of Nissan engine with capacity equal to 3.5 liters V6 and since 2002 it has been used on Nissan Murano, and later (2007) modification for rare Maxima, Pressage, and for some time past installed on Teana of the Russian assembly.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD/AWD		10,1	6	CVT Fluid NS-2

Technical issues and repair guidelines

The delicate usage with a long oil heat-up and frequent oil change (NS-2) accompanied by the torque converter repair is the best way for a car owner to preserve CVT during the first years of operation.

Typical problems of “old” CVTs RE0F09A:

In general, this CVT family is one of the most reliable in the world and these transmissions have been a standard in the world of transmission manufacturers for a long period of time. But this CVT lost competition on the market of 3-4 liter cars to automatic gearboxes and even to DSG. The typical overhaul of this CVT requires the torque converter repair. Common problems of “old” CVTs are related to the pressure control valve (of the pump) wedging caused by overheating and contamination in summer time. The valve can wedge and switch-on after a heat-up, that leads to the dynamic load on transmission components and rapidly damages the belt and cones.

The long-term operation with contaminated oil wears out valves and plungers of the valve body. The most popular spare part for JF010E is a driving belt. The first reason of rapid belt wear-out is related to insufficiently warmed up transmission in winter time. The second reason of the belt damage is the driving at low speeds in traffic jams with harsh accelerations. The most common reason of damage for surfaces of the belt and shafts is related to the oil cleanness.

- Forward Clutch is exposed to burning in most cases. It is also common to replace Reverse clutches.

- Sometimes orders for repair include the step-motor which has quite limited operational life in overheated oil ( as in JF011).

The main factor for operational durability of this transmission is related to the state of shafts (input and output) which are unique in terms of design. The surface of cones is the main resource of this transmission. All other units of this gearbox are much cheaper or easily operate during two service lives of this CVT.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Renault	MEGANE	09-11	CVT FWD	L4 1.9L
Renault	SCENIC	09-11	CVT FWD	L4 1.9L

How to repair this transmission (Videos)

Murano CVT Transmission Repair Part 1

Murano CVT transmission Repair Part 2

Murano cvt transmission repair part 3

Murano cvt transmission repair Part 4

CVT transmission repair Part 5

CVT Transmission Repair Part 6

Instruction manuals and useful links

Link type	Source	Description
0	Sonnax	Valve Body Layout JF010E (RE0F09A)

KM175 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Standard automatic transmissions KM175-5, 176, 177-5,6,7/8 (another name- F4A21-F4А22) found application in FWD Mitsubishi cars. This transmission has been installed on Mitsubishi Galant, Sonata,...etc since 1988. It was developed on the basis of a successful 3-speed family KM170. This family of FWD automatic transmissions was actively installed on Hyundai Elantra, Sonata, Excel etc. It was also installed on budgetary cars Dodge, Plymouth, etc. The new series of 4-speed automatic transmissions named as A4AF-1 (and its modification A4AF-2, A4BF-2) was designed by Hyundai AT-department under the supervision of Mitsubishi in 1992 on the basis of КМ175 series for small cars Hyundai.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		5,8	3	SP-III

Technical issues and repair guidelines

It’s a popular series of transmissions from Mitsubishi – Hyundai and one of the most popular Mitsubishi transmissions in repair services. Owners of cars with this type of transmissions prefer a cosmetic repair by their own forces or replacement with the used transmission.

The repair kit of gaskets and seals is ordered together with the kit of friction components. Rarely, owners decide to perform a classic reassembly and additionally order the kit of steel discs. For cars with short mileages and normal pressure state in packages, it will be enough to replace the filter (for series КМ175-177) and change ATF.

Seals are usually replaced because of fluid leakages between the transmission and the torque converter unit, which is considered to be a sign of the torque converter wear-out. Bushings and all rings are replaced in order to restore the pressure in packages. Firstly, frictions burn in Forward/Direct packages (with steel discs), then its turn for friction clutches of the package Overdrive with steel discs and the Low/Reverse package. In most cases, replacement of spare parts and friction elements is accompanied with replacement of the brake band (Kick-down). The electrical mechanism of this transmission is very reliable, and only solenoids,which reached the end of their service life, should be replaced. Before solenoids replacement, it is recommended to check the wiring integrity.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	COLT	92-94	4 SP FWD	L4 1.8L
Eagle	SUMMIT/SUMMIT WAGON	93-96	4 SP FWD	L4 1.8L
Eagle	TALON	90-94	4 SP FWD	L4 1.8L 2.0L
Hyundai	ELANTRA	92-96	4 SP FWD	L4 1.8L
Hyundai	SONATA	91-98	4 SP FWD	L4 2.0L
Mitsubishi	EXPO LRV	92-93	4 SP FWD	L4 1.8L
Mitsubishi	GALANT	89-93	4 SP FWD	L4 2.0L
Mitsubishi	MIRAGE	93-97	4 SP FWD	L4 1.8L
Mitsubishi	PRECIS	90-95	4 SP FWD	L4 1.5L
Plymouth	COLT/COLT VISTA	92-94	4 SP FWD	L4 1.8L
Plymouth	LASER	90-94	4 SP FWD	L4 1.8L 2.0L

F1C1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The F1C1 CVT solution has been applied on FWD cars (Colt and Lancer) with engines of approx. 1.5 liters since 2000.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	145	7,8		CVT Fluid NS-1

Technical issues and repair guidelines

The transmission fluid for this CVT has unique qualities, namely, when the oil is hot it becomes "sticky", allowing the belt to stick to cones without slipping. Therefore the fluid should be kept clean and the filter should be replaced when the oil loses its transparency. The belt slippage damages the belt itself and cones (the main CVT unit).The fluid is heavily contaminated by friction elements and loads wear the belt protector that increases the possibility of the belt slipping and wearout of cones surface. Frequent change of fluid and filter significantly prolongs the resource of this transmission.

Advantages of of this CVT frequently turn out to be its porlems. The push belt of this CVT (as in JF011E Jatco) has a comparatively short resource and almost became a "spare part", especially if the driver likes accelerations without the warm-up. The repair kit of gaskets and seals is ordered for rebuilding of this transmission.

CVT components have the following problems:

Issue with the Forward drum consist in damage of the stop ring, rapid wear-out of the Forward frictions leading to contamination of even fresh ATF. The problem reveals itself in the failure of moving forward. It is recommended to replace not only the burnt drum, but also the belt with the filter.Cones are not subjects for repair or grinding, therefore sometimes they are replaced with used cones which have some resources.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Citroen	RVR	12	CVT FWD	L4 1.6L
Mitsubishi	COLT PLUS	04-14	CVT FWD	L4 1.5L 1.6L
Mitsubishi	DION	00-05	CVT FWD	L4 2.0L
Mitsubishi	LANCER	01-16	CVT FWD	L4 1.5L 1.6L 1.8L

How to repair this transmission (Videos)

F1C1A

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme F1C1
web	www.at-manuals.com	Scheme F1C1

TF80SC Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed front drive automatic transmission AW TF80SC (AF40-6) has been available on the market since 2003 as more expensive alternative of the 4-speed AW50-40 and the 5-speed AW55-50 for 2-... 4-liter cars: Ford (as AF40-6), Mazda (as AW6A-EL), Volvo, SAAB, Opel, Fiat and all "French" automakers Peugeot-Citroen-Renault (as AM6).

The family of AW TF80SC transmissions has two different sub-modification, for two classes of engines: "middle class" (up to 2.0 liters)- AF40-6\TF80SC and AF21\TF81SC - "heavy duty" (2.0 - 4.0liters) and has the torque capacity of up to 450 Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/AWD	450	7	3,8	Type T-IV

Technical issues and repair guidelines

The torque converter intensively contaminates the ATF with dust from carbon friction lining. Almost each transmission repair includes cutting of the torque converter and replacement of the friction lining. The worn-out friction lining of the torque converter has a negative impact on the valve body. The more aggressively the driver pushes on the gas pedal, the earlier the computer switches on the slipping mode of the torque converter friction, resulting in rapid wear-out of friction plates and the necessity to rebuild the the torque converter and the valve body. This transmission is sensitive not only to contaminated oil, but also to the wear-out of teflon rings (where oil leakages may occur). The operation with worn-out spare parts leads to burning of frictions, and later to problems with solenoids and the valve body.

The whole kit of friction discs is replaced in case of burnt oil. The package С2 (4-5-6) is usually the first to burn (in some cases it may be the package 1-2-3-4 Clutch (C1)). The standard kit for reassembly includes the kit of pistons. (С2 piston+retainer, retainers С1 and С3). The kit includes the most popular pistons ordered by transmission specialists. In case of burnt ATF, it is also recommended to replace the Reverse brake band , because its friction lining is affected by burnt ATF. The problem of frictions burning are usually related to the wear-out of teflon rings.

The pump bushing turns out to be the most vulnerable part in the TF80 transmission, in case of the torque converter parts wearout. Problems may also occur in the differential (in AWD Mazda CX7, CX9). The problem lies in the spline failure. This issue is caused by the ECU settings, allowing overloading.

Generally, the TF-80SC transmission is extremely reliable and successful 6-speed unit, which causes less problems in comparison with its predecessors TF60SN and AW55-50. It may be considered as an “invincible” solution and the most maintenance-friendly 6-speed automatic transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	REGAL	12	6 SP FWD	L4 2.0L
Cadillac	BLS	06-09	6 SP FWD	L4 1.9L V6 2.8L
Cadillac	SRX	09-11	6 SP F/4WD	V6 2.8L
Opel / Vauxhall	SIGNUM	05-08	6 SP F/4WD	L4 1.9L 2.8L 3.0L
Opel / Vauxhall	VECTRA	05-09	6 SP F/4WD	L4 1.9L V6 2.8L 3.0L

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme TF80
pdf	www.at-manuals.com	Valve body valves
web	www.at-manuals.com	Solenoid application chart
pdf	Sonnax	Valve Body Layout TF80SC
pdf	Sonnax	Valve Body Layout TF81SC

A999 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 3-speed automatic transmission A999 (also referred 32 RH) was produced by Chrysler. This transmission is very similar to the A904 transmission. It is equipped with 5 direct friction discs. Both automatic transmissions A999 as well as A904 have lower 1-st and 2-nd gear ratios, which help low-capacity engines to ensure better acceleration without any losses to highway fuel efficiency.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD		8,5	4,2	Mopar ATF+3

The A999 transmission is commonly applied in XJ or YJ models with the engine capacity of 4 liters. The main difference between A999 and A904 consists in the rear band, which holds the planetary gear carrier: the band used in the 32RH transmission is more efficient. This gearbox is considered to be quite reliable, so it commonly outlives other stock components.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	PICKUP/RAM	00-02	3 SP R/4WD	V6 3.9L
Dodge	VAN/WAGON 1500-2500	95-03	3 SP RWD	V6 3.9L

How to repair this transmission (Videos)

Fixing a leaking shift shaft seal A999

Instruction manuals and useful links

Link type	Source	Description
web	advanceadapters.com	999 (32RH) TORQUEFLITE
pdf	parker.com	Scheme 32RH

RE5R05A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic gearbox RE5R05A with the longitudinal positioning was used since 2000 on all powerful RWD models of Nissan as well as on Infinity with engine capacities 2.5 -6 lit.

There are a lot of various sub-versions of the RE5RO5A solution for various torque and various types of cars, which are distinct in filters, friction components, steel discs, hard parts, and valve body. All sub-versions are founded on very fail-safe construction of RWD Nissan 4-speed automatic gearboxes, which were modified with the Overdrive planetary gear and more intellectual electronic control.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD		10,5	4,2-5	Nissan Matic-J

Technical issues and repair guidelines

Typical major repairs of this transmission involve the torque converter (TC) repair, reassembly, cleaning and change of friction elements, oil and filter, and repair kit of gaskets and seals. The main repoair issue of this transmission is caused by aggressive accelerations leading to fast wear-out of the TC locking unit, resulting in wear-out of channels and valves of the valve body. Consequently, the pressure shortage takes place in different packs depending on the computer settings provided by the automaker and driving style of the car owner. The brake band is also considered to be a spare part in this gear shifting unit. On powerful and heavy vehicles, the brake band may distort the drum. This part is commonly replaced during major repairs, when the car comes to the repair service after travelling 200 thousand kilometers or gets for repair with burnt fluid, burnt frictions and steel discs.

The unpredictability of vulnerabilities of this transmission is attributed to the point that this smart system was adjusted for many various cars. The wear-out of channels of the valve body and solenoids takes place in distinct areas for different models resulting in the oil pressure loss in various areas of the gearbox. The abovementioned issue results in rapid wear-out of frictions. In Nissan Pathfinder, Infinity etc, the valve body failure is specified by the following caption "Check Engine". It is one of three typical problems with the valve body and sensors. The other two problems are breakdown of solenoids and wear-out of valve body channels.

It is advisable to change fluid in this transmission more frequently, not waiting before it becomes opaque. When performing the fluid change on a timely basis, the valve body may operate properly even after 200 thousand kilometers and the overhaul may be delayed until 300 thousand kilometers. The valve body rebuilding is performed in rare cases. More frequently, this component is cleaned or changed by the new one. Issues of the valve body may be divided into mechanical (wear-out) and electrical – breakdown of sensors, wiring, solenoids, circuit boards of the valve body.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Gonow	AOXUAN G5	10-16	5 SP RWD	L4 2.4L
GreatWall	HOVER H5	10-14	5 SP R/4WD	L4 2.0L
GreatWall	HOVER H5/H7	12-13	5 SP RWD	L4 2.0L 2.5L
Haval	HOVER H5	14-16	5 SP R/4WD	L4 2.0L
Hyundai	GENESIS COUPE	08-12	5 SP RWD	L4 2.0L
Hyundai	GENESIS COUPE	08-16	5 SP RWD	L4 2.0L
Hyundai	H350	15-16	5 SP RWD	L4 2.5L
Hyundai	PORTER	12-16	5 SP RWD	L4 2.5L
Hyundai	SOLATI	15-16	5 SP RWD	L4 2.5L
Hyundai	STAREX	07-16	5 SP RWD	L4 2.5L
KIA	BONGO TRUCK	12-16	5 SP RWD	L4 2.5L
KIA	BORREGO	09-10	5 SP R/4WD	V6 3.8L
KIA	MOHAVE	07-16	5 SP R/4WD	V6 3.8L
KIA	SORENTO	02-12	5 SP R/4WD	L4 2.5L V6 3.3L 3.5L 3.8L

How to repair this transmission (Videos)

RE5RO5A Teardown Inspection

P1757 Front Brake Solenoid Circuit

RE5R05A - TCC Shudder

RE5RO5A Part 1

RE5RO5A Part 2

RE5RO5A Part 3

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual RE5R05A
web	www.at-manuals.com	Scheme RE5R05A
pdf	Sonnax	Valve Body Layout RE5R05A
web	Sonnax	Measure the TCC Plunger Valve to Avoid RE5R05A Pressure Problems
web	Sonnax	Converter SHUDDER After a Radiator Cooler Failure Repair
web	Sonnax	RE5R05A Facts and Observations

A860E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed transmission Aisin А860Е was designed in 2005 for trucks Hino Dutro (Toyota Dyna) 300 and hit the Japanese market in 2006. However, the mass production of this “invincible” unit was started in 2009.

This transmission transmits the torque up to 420 Nm from diesel engine with the capacity 4 liters. This transmission is the main competitor of the Allison 3000 transmission.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD	420	12		Toyota T-IV

Technical issues and repair guidelines

This transmission is very reliable as all RWD Aisin transmissions. The repair of this transmission in most cases includes oil and filter replacement.The transmission reassembly requires the repair kit of gaskets and seals with valve body spare parts, which are ordered because of sealing rings, which wear out earlier than all other spare parts and gaskets.

The electrical part of this transmission is maximally unified: the valve body has 3 simple and invincible On-Off solenoids, 3 interchangeable linear solenoids ( А, C, D solenoids according to the manual), responsible for an ideal gear shifting and a linear solenoid (B). Solenoids usually are quite reliable, but in case of any issues related to the valve body, solenoids are considered the main cause of these problems. Aisin valve bodies produced after 2009 are notable for enhanced durability and are almost not ordered for replacement.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hino	DUTRO	99-16	6 SP RWD	L4 4.0L
Toyota	COASTER	97-16	6 SP RWD	L4 4.0L

A540E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission А540E produced by Aisin Warner has been used since 1989 on AWD and FWD 2- 3 liter Toyota Camry, RAV4, Sienna and Lexus ES250 and ES300. In terms of design, this transmission is the part of А140 - А240 series with interchangeable parts, but it can transmit a higher torque. There are several sub-modifications of this transmission.

The most significant design changes were introduced in 1994 for А541E used with 3-liter engines, this gearbox differs in friction components of the 2-brake package andadditional 4-th solenoid of the torque converter lockup in the valve body. Tested design, simple electrical components and most importantly control settings that made it impossible to load components of this transmission to maximum torques – all these conditions ensured high reliability parameters of the A541 unit and durability of this transmission.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/4WD	280	8	3	Toyota Type T-IV

Technical issues and repair guidelines

There is no much information on the repair of this transmission, because it operates for a long time without any problems, therefore it is hard to point out any soft spots in А540-541 transmission units. It has been reported that the first released gearboxes (A540H before 1991) had some issues with the reverse gear. The most common reason for appearance of these transmissions in repair services is related to the change of oil and replacement of filter (for А541Е Camry V6).

The А540E unit usually gets in repair service with worn-out torque converter frictions causing clogging of the valve body and solenoids, resulting in the pressure shortage in packages (frictions and discs get burnt) and short supply of the pump lubrication (bushing and seal burn and leak).Problems of А540E (А541E, 540H) are commonly related to ill-timed preventive measures for the torque converter, and have nothing to do with durability of this robust transmission capable of covering one million kilometers (standard for Toyota) with just few replacements of the torque converter lockup and ATF change.

Usually at the early stages of wear-out of old Toyota cars owners restrict repair actions to the low-cost repair-cleaning of the valve body with replacement of seals and the pump bushing.The repair process obviously includes the pan gasket replacement. When taking more serious approach to the overhaul of used transmission, it is common to replace all gaskets and seals kit. After the overhaul, this transmission can operate until the end of the car service life.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	ES	90-01	4 SP FWD	V6 2.5L 3.0L
Toyota	CAMRY	88-93	4 SP FWD	V6 2.5L 3.0L
Toyota	CAMRY GRACIA	00-01	4 SP FWD	L4 2.0L 2.2L V6 2.5L
Toyota	RAV4	96-00	4 SP F/4WD	L4 2.0L
Toyota	SIENNA	98-03	4 SP FWD	V6 3.0L

How to repair this transmission (Videos)

A540E teardown

Toyota Avalon Transmission A541E

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Manual A540E
pdf	www.at-manuals.com	Scheme A540E

A440F Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Automatic transmissions A440 and A442 are very reliable units. Repair services for these transmissions resemble the repair of manual transmissions.These 4-speed automatic transmissions were installed on "invincible" and powerful Land Cruiser with the engine 4 liters since 1985 up till 1995 (440F), and then from 1993 the A442F modification made this transmission family of Aisin Warner very popular as well as А340 (AW30-40LE).In 1998 electrical components and the valve body of the A442F. It is a low-maintenance transmission in regard to ATF status, but the fluid cleanness should be taken into consideration.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/4WD	420	15	6	Dexron III, VI

Technical issues and repair guidelines

The А440 - 442 units are notable for their reliability and even 20-year old transmissions basically require only replacement of friction filters and repair kits.The torque converter with worn-out lockup clutch is frequently repaired in this transmission. After 10-12 years of service all gaskets, seals and rings get worn and fragile, therefore they should be replaced. The replacement of spare parts of the repair kit gives this transmission additional 3-5 years of service life. The Precision overhaul kit is used more often than Transtec overhaul kit.The first spare parts that get worn-out are teflon rings and frictions of Forward and Direct packages.

The pump cover bushing is a common component to be replaced in these “invincible” transmissions. This problem may be caused by the worn-out torque converter, overheating, clogged valve body or ageing of the transmission itself.The planetary gear Forward is the first to get out of order in old Land Cruisers. It’s a rare case when in this gearbox you get burnt drums, pump gears, valve body, torque converter, but when it happens the structure of this transmission is not to blame, except for the fact that it is allowed to heat the oil with slipping up to 150 С. It is said that after the overhaul this simple and resourceful transmission starts a new service life. This family of transmissions has a long service resource, that allows us to call this transmission “invincible” under conditions of sufficient cooling and timely fluid change.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Toyota	LAND CRUISER	88-92	4 SP 4WD	V6 4.0L 4.2L

How to repair this transmission (Videos)

A442F Automatic Transmission Service

Landcruiser Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme A440F

A24A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

First of all Japanese engineers pay much attention to the reliability rate when manufacturing automatic transmissions. Reliability became an important factor when Japanese specialists decided to produce 4-speed automatic transmission M4TA (released in 1997) without planetary gears. The advantage of this solution is considered to be improved reliability. But it the same time it should be noted, that such transmissions have a massive size, therefore it complicates the process of repair. The automatic transmission M4TA was installed on Honda Civic, Odyssey, Prelude, Accord, crossover CRV. The maximum engine capacity allowed for this transmission equals to 2,4 liters.

Honda CIVIC; 92-95 4 SP FWD L4 1.5/1.6L; Honda A24A

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		5,9	2,7	Honda Z-1

Technical issues and repair guidelines

As it has been mentioned above the automatic transmission M4TA is notable for its enhanced reliability. The car owner only needs to regularly change the oil with filter elements. It is required to use high-quality transmission oil, that preserves bushings and friction clutches from wear-out.

In most cases it is required to perform the overhaul after travelling 300.000 kilometers or more. At the same time it should be noted, that improper operation of the transmission and aggressive driving behavior may lead to frequent malfunctions resulting in the overhaul after running 100.000 kilometers and even earlier. Therefore it is necessary to point out, that this transmission is mainly intended for operation in urban environment.

In the list the most frequent malfunctions we should point out problems with seals and rubber-covered gaskets. Rubber covered linings may get out of order rapidly leading to oil leakages. In this case it is required to replace rubber covered gaskets and seals. Implementation of these repair procedures may be troublesome because of the transmission dimensions. The pan disassembly is a complicated procedure and should be performed in the service facility. In the process of overhaul specialists perform the valve body state check, replacement of friction clutches and drums. In some specific cases it is required to replace burnt clutch. Generally this transmission makes a good impression, distinguished by reliability and repairability.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	CIVIC	92-95	4 SP FWD	L4 1.5L 1.6L

How to repair this transmission (Videos)

S24A/A24A/M24A

Honda Civic Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
0	www.at-manuals.com	Scheme

A240 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This family of 4-speed automatic gearboxes 240 (А240 - 245, А246Е etc.) has been used since 1985 on famous and reliable Corolla as well as on Corona, RAV4 models with engine capacity up to 2 liters. The А246 unit without any significant updates is still used on Corolla and RAV4.This line of gearboxes also includes А140-series intended for higher torque. The A140E unit had been used since 1983 up to 2004 on more powerful Camry (with the engine capacity from 2 liters) assembled in the USA and Japan.

At the same time, a bit more sophisticated and highly-priced version named А540 was produced for even more powerful engines of Camry and Lexus. The modern line generation of this transmission family ( A245E/ A246E /247Е) hit the market in 2003. The А247Е model has a bit more improved hard parts aimed to endure higher torque from 2-liter engines. In 2003, the valve body was modified one more time: the unit received a linear solenoid of main pressure, the filter with a pan, as well as a significant improvement of the software part.

Despite the fact that this gearbox is not complicated and has a low price, the family of these 4-speed gearboxes is not so popular as more "sophisticated" Aisin analogs of "U" series. The market rivals of this gearbox are not German ZF4HP16 - 4HP18, competing with U240, but Jatco's 4-speed RE4F03 - RE4F04 units.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	186	7,2	3,1	Toyota Type T-IV

Technical issues and repair guidelines

Overhauls in repair services commonly consist of repair of the torque converter, valve body, gearbox reassembly and replacement of spare parts and burnt friction components. Usually during the overhaul specialists have to deal with old gearboxes having the lockup mechanism worn to the glue layer, which reaches other frictions. Therefore, it is advisable to replace the whole set of friction discs during reassembly procedure. For problem-free exploitation of this gearbox, it is required to change fluid and (after 8-10 years) replace the filter on a timely basis. It is also recommended to replace the filter, if the gearbox has been used with burnt fluid or worn friction in the torque converter.

The most sensitive issue for the A240 unit is the wear-out of the lockup friction in the torque converter (TC) clutch which makes solenoids and valve body dirty.These gearboxes can cover substantial distances without any repair, but after 200 thousand kilometers it is advisable to monitor possible leakages of the pump seal and timely perform repair of the TC unit. Seals (of pump, axle shaft, cuffs etc.) start leaking because of a long exploitation period or due to wear-out of the TC lockup and resulting vibrations. The transmission shaft seal is replaced together with other seals. When delaying with replacement of seals, then it may be needed to change the rotating pump bushing.Solenoids are quite durable as well as, the brake band. The design of these elements hasn’t been changed since 1985.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Daihatsu	APPLAUSE	0	4 SP F/4WD	L4 1.6L
Pontiac	VIBE	03-09	4 SP F/4WD	L4 1.8L
Pontiac	VIBE	04-07	4 SP F/4WD	L4 1.8L

How to repair this transmission (Videos)

A140E Solenoid Test

Teardown - Rebuild A140E

Tranny Sub-Assemblies A140E

Transmission Assembly A140E

Transmission Assembly A140E p.2

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme A140
pdf	www.at-manuals.com	Repair manual A140
pdf	www.at-manuals.com	Scheme A240
pdf	www.at-manuals.com	Repair manual A240

6R140 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

6R140 is one of the most reliable automatic transmissions created by Ford. Repair specialists of the company introduced a durable single-piece bell shaped construction for 6R140. This construction is notable for its stiffness. The gearbox has a deep first gear with a double overdrive.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	AWD		16,5	8,5	Mercon LV

Technical issues and repair guidelines

The Lepelletier toothed gearing solves the problem of matching gearboxes’ gear sets and clutches. So this gearbox employs just 5-clutch sets to get 6 forward gears. 6R140 is reinforced by the usage of a metallic powder carrier within the compounded gear set. The carrier consists of four compressed elements, which are forced together to form a hard composition. 6R140 has a new torque converter which contributes to longer operability and a high-powered turbine damping mechanism introduced to smooth the force from the engine.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	F-250	11-16	6 SP RWD	V8 6.2L
Ford	F-250/350 SUPER DUTY	10-16	6 SP R/4WD	V8 6.2L 6.7L
Ford	F-350/450/550 CAB CHASSIS	16	6 SP R/4WD	V10 6.8L V8 6.2L 6.7L

How to repair this transmission (Videos)

Transmission Disassembly and Identification

6R80 Teardown

Fluid and Filter Replacement

6R140W Intro ATRA

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout 6R140
pdf	Sonnax	Vacuum test 6R140

6F50 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of 6-speed automatic transmissions Ford 6F50 / 6F55 was designed jointly with GM for FWD and AWD vehicles Ford with engines capacity up to 3.5 liters. This transmission is used for powerful Explorer and Taurus with gasoline engines (3.5 liters) and diesel engines (2.5 liters) and intended for a maximum torque equal to 380 Nm. In two years more advanced modification 6F55 was released for the torque equal to 407 Nm and engine V6 (3.5 liters). The list of cars with transmissions of this family is constantly growing. Over the last years these transmissions found application on Mazda Tribute and CX-9, Mercury Mariner, Milan etc. 6F50 is also classified as 6T70 by GM.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/AWD	380	9,5	5	Mercon LV

Technical issues and repair guidelines

The 6T70 unit is considered to be more problematic in comparison with Ford modification. 6T70 had many problems related to electrics and transmission components. In 2012 several significant updates were introduced with addition of wavelike rings in packs and performance optimization of solenoids plate and the valve body.

The 6F50 / 6F55 (GM 6T70 / 6T75) transmissions found application on rare American vehicles. For rare overhauls specialists usually order the filter with the pan gasket, which should be replaced with ATF after 50-80 thousand kilometers.It should be taken into account that for this class of automatic transmissions it is crucial to monitor the ATF state (DEXRON-VI - GM or Mercon 5 - Ford) and its temperature. The quantity of fluid required for full change is approx. equal to 9.5 liters. It is advisable to repair the torque converter and clean the valve body when having problems with shifting and operation of the valve body with solenoids.

A quick failure of the torque converter caused by contaminated fluid may be considered as a soft spot of this transmission. This problem leads to oil starvation or increased pressure and cranking of bushings. The valve body is repaired by replacement of worn valves with enlarged valves from Sonnax. Problems of this transmission often start with the wear-out of rings and bushings. Contaminated fluid from the torque converter speeds up the wear-out of these seals and damages solenoids.This transmission rarely gets in repair services as well as cars with this good automatic transmission produced by Ford.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	EDGE	06-16	6 SP F/4WD	V6 3.5L 3.7L
Ford	EXPLORER	10-16	6 SP F/4WD	V6 3.5L 3.7L
Ford	FLEX	08-16	6 SP F/4WD	V6 3.5L
Ford	FUSION	09-12	6 SP F/4WD	V6 3.5L
Ford	TAURUS	07-16	6 SP F/4WD	V6 2.7L 3.5L 3.7L
Lincoln	MKS	08-16	6 SP F/4WD	V6 3.7L
Lincoln	MKT	09-16	6 SP F/4WD	V6 3.7L
Lincoln	MKX	06-14	6 SP F/4WD	V6 3.7L
Lincoln	MKZ	12-16	6 SP F/4WD	V6 3.7L
Mercury	SABLE	08-09	6 SP F/4WD	V6 3.5L

How to repair this transmission (Videos)

TSS and OSS sensor removal and installation

6F50 overheating problem

Drivers Side Axle Seal Replacement

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 6t70
pdf	Sonnax	Valve Body Layout 6F50
pdf	Sonnax	Valve Body Layout 01JGM 6T70 (Gen. 1), 6T75 (Gen. 1)
pdf	Sonnax	Vacuum test GM 6T70 (GEN. 1), 6T75 (GEN. 1)
pdf	Sonnax	Vacuum test 6F50, 6F55
pdf	Sonnax	How Small Changes Led to the New Form & Function of Gen. 2 6T70/75 Valve Bodies
pdf	Sonnax	GM Gen. 1 6T70/75/80 \| Ford 6F50/55 Concerns & Repair Techniques

6F35 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission 6F35 (6F30) is a collaborative investment project of Ford with GM released in 2002. With regard to transmission components 6F35 is practically a complete analog of the GM 6T40- 6T45 transmission, details for manufacturing of these transmissions are unified to the fullest extent and differ only in electrical elements, filters, and pans. This transmission has been installed since 2008 on popular American FWD and AWD vehicles of Ford (Kuga, Focus, Escape, Fusion...) and Mazda (Tribute) with the engine from 1.6 up to 3 liters. There are two different modifications of the 6F35 – with engines less than 2.5 liters and 3 liters engine. The design of the 6F35 is based on the flagship model 6F50 /6F55= 6T70 /6T75, constructed on modular principle of maximum standardization and interchangeability of blocks.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/AWD	350	8,5	4,8	Valvoline MaxLife Multi-Vehicle ATF / Mercon LV/ Motorcraft XT-10-QLVC

Technical issues and repair guidelines

In most cases repair procedures f6F35 transmission consist of oil (DEXRON®VI or original XT-10-QLV) change and filter replacement. This transmission is very sensitive to the ATF level. It has no ATF level gauge and its levellevel is tested in compliance with the overflow stopper. As all 6-speed transmissions, the 6F35 (6F30) is sensitive to loads when the ATF is cold.

Many complaints have surfaced about erratic gear shifting, with gears harsh engagement and sometimes even slipping out of reverse or forward gear. The problem is most pronounced when the car is on the road, and happens when the transmission is stuck in one gear. It has been found that moving components within the transmission can create more friction, leading to issues requiring repair.

The 6F35 Transmission in Ford Fusion and Ford Perform cars is particularly prone to overheating issues. It is important to ensure that the control unit settings are adjusted appropriately, and also that the driver’s driving style is suitable for the vehicle. A dogged cooling system with less than optimal capacity has been found to depend on overall performance, so it may be worth removing Automatic Transmission Fluid (ATF) from the car.

This is one of the most common problems with 6F35 conventional 5-speeds transmission issues, and can be easily rectified by a keen driver. The 6F35 transmission offers better fuel economy than its conventional 5-speeds counterparts and covers their 6f35 cars in Ford, covering over 50,000 miles in some cases. It is also good for long run drivers as it provides a greater gear span and optimal speed load combinations with much better optimal combinations.

The 6F35 Transmission has a number of design flaws which can cause problems for drivers. One of the most common issues is that the transmission tends to drag engine rpm when shifting gears, especially when towing heavy loads. Another started problem is reluctance or little reluctance when starting off from a complete stop, especially on mountain roads or when driving in stop and go traffic on a Saturday afternoon. Towing is usually the most common cause of transmission problems as it runs the engine harder than normal and can cause significant wear on components over time. The 6F35 Transmission has been known to be reliable but certain design flaws can cause problems if not addressed properly.

One common issue is that the computer commanded 1st gear and 5th gear command will switch when read drive is commanded by the computer. This can be easily fixed by changing the range switch to read range switch and ensuring that the input speed sensor is operating properly. Another issue is when the shifter is moved, the rpm figure drops about 200 rpm from its original figure of around 2. This happens for a short time and can cause a few issues if it happens multiple times.

One of the most common 6F35 transmission problems is a failed one way clutch. This clutch can cause the wheel speed signal to be lost which will limit engine power and prevent the vehicle from moving. If this happens, it may be necessary to replace the converter. Additionally, if equipped with a problem vehicle, there may also be an issue with floor shift selector lever and display shifts. In some cases, it can even cause a push button start to not work correctly or no throttle response when starting the vehicle.

6F35 Transmission Problems And Possible Solutions can include malfunction valves, control valve, and the valve body separator plate. The malfunction can cause a compromise cooling in the heat exchanger. As a solution on transmissions, it is important to install a fluid heater in order to properly lubricate the transmission. Additionally, removing check ball is necessary to allow for proper flow of transmission fluid. It is also recommended to install a fluid cooler before any additional modifications are done. When using Mercon LV transmission fluid, it is important to note that the deleted hole must be drilled back into the valve body separator plate in order for it to pass proper flow of coolant from one side of the transmission dipstick tube over to the other side.

This external cooler bypass valve is necessary for the proper flow of coolant in order to prevent overheating and eventual transmission failure. If an experienced fluid leak is present, it can lead to a deteriorating fluid which compromises lubrication, leading to deterioration of internal components and eventually catastrophic failure of the transmission. Ford Fusion cars that are experiencing 6F35 transmission issues may be left with a failing left half shaft seal or other related issues if not addressed properly.

If you are having transmission problems, post your car in our cars section to see if others are having the same issues. Certain problems may be resolved with a simple transmission fluid flush or replacing the left half shaft seal. On our 2015 Ford Explorer, we had to completely rebuild the transmission and it was a costly endeavor. To keep track of any potential issues with your car, it is best to keep a log of when you drive your car and the mileage each time.

This can help you detect any problems with your 6F35 transmission early on. I recently had to repair my 6F35 transmission, and Ford sent me a rebuild kit to fix the inherent 6f35 problems. I took my car to the repair shop and they were able to use the kit from Ford to fix the problem. If you are not comfortable with fixing the issue yourself, I would advise you to take your vehicle into a dealership for them to look at it. They may be able to provide you with a powertrain warranty for any potential issues that may arise in the future. If this does not work, then Ford may even send your mechanic out a kit so they can use it in order to fix it up for you. However, this does not always guarantee that the problem will be fixed as some of their kits use faulty factory parts which could just postpone any inherent 6f35 problems until later down the line when they appear again.

In order to make sure that this doesn’t happen, it is a good idea to bring the car to a repair shop and have an experienced technician install the unit. The technician will also be able to use engine and transmission data as well as perform line pressure checks, hook pressure transducers, and hook cases to the mainline pressure port.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	EDGE	11-16	6 SP F/4WD	L4 2.0L
Ford	ESCAPE	08-16	6 SP F/4WD	L4 1.5L 1.6L 2.0L 2.5L
Ford	EXPLORER	11-16	6 SP F/4WD	L4 2.0L 2.3L
Ford	FOCUS	14-16	6 SP FWD	L4 1.5L
Ford	FUSION	09-16	6 SP F/4WD	L4 1.5L 1.6L 2.0L 2.3L 2.5L
Ford	GALAXY	15-16	6 SP FWD	L4 1.5L
Ford	S-MAX	13-16	6 SP FWD	L4 1.5L 2.0L
Ford	TAURUS	13-16	6 SP FWD	L3 1.5L L4 2.0L
Ford	TRANSIT CONNECT	13-16	6 SP FWD	L4 1.6L 2.5L
Lincoln	MKC	14-16	6 SP F/4WD	L4 2.0L 2.3L
Lincoln	MKZ	12-16	6 SP F/4WD	L4 2.0L
Mazda	TRIBUTE	08-11	6 SP F/4WD	L4 2.3L 2.5L V6 3.0L
Mercury	MARINER	09-10	6 SP FWD	L4 1.6L 2.0L 2.5L V6 3.0L
Mercury	MILAN	09-10	6 SP F/4WD	L4 2.5L V6 3.0L

How to repair this transmission (Videos)

6F35 Oil (Fluid) Change procedure on 2009-2012 Ford Explorer Escape Fusion

ATF Fluid Change on 2013-2019 Ford Explorer Escape Fusion

LH Axle Seal Leak Repair in 6F35 transmission

6F35 Full Rebuilding Process

Highlights and Valvebody

6F35 Teardown

6F35 Calibration Program

Solenoid Body Strategy Programming

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Vacuum test 6F35 (Gen. 1), 6F35 (Gen. 2)
web	Sonnax	Solenoid Differences Between 6F35 Gen 1. & Gen. 2
web	ATSG	6F35 Repair Manual
0	Unknown	Installation Guide for 6F35
0	Transmission Digest	6F35 Overheating Issues Solution
0	Sonar	Solving One-Way Clutch Failure on Ford 6F35 Torque Converter

68RFE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission 68RFE produced by Chrysler has been installed since 2006 on pickups Dodge RAM 2500-3500 with engine capacity of 6 liters and higher. In terms of design, this transmission is based on 45RFE and on the 5-speed 5-45RFE.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	AWD		15,7	6,5	Mopar ATF+4

Technical issues and repair guidelines

During the reassembly, specialists use the following repair kits:

-Kit of gaskets and seals or a complete kit of gaskets, seals, frictions and steel discs (Master Kit)

- Kit of pistons (5 pieces). Many details and spare parts are common with the 5-45RFE.

- The complete kit of friction components is ordered for the automatic transmission reassembly.

The valve body and the block of solenoids are the main vulnerabilities for the 5-45RFE transmission. After 100 thousand kilometers, it is required to monitor the state of these components (oil pressure, cleaning). The valve body and solenoids often reach the end of their service lifespan after 3-5 years of active exploitation, especially with the worn torque converter clutch.

There are problems with the 68RFE torque converter (overrunning clutch, friction, gaskets). It is recommended to replace spare parts in the torque converter quite early, because of problems related to American torque converters.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	PICKUP/RAM 2500-3500	09-16	6 SP R/4WD	L6 6.7L

How to repair this transmission (Videos)

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Introduction to the 68RFE
pdf	www.at-manuals.com	Scheme 68RFE
pdf	Sonnax	Valve Body Layout 68rfe
pdf	Sonnax	Vacuum test 45RFE, 545RFE, 65RFE, 66RFE, 68RFE
web	Sonnax	Solving the 6R80 Transmission Leak Mystery

5HP30 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission ZF5HP30 is one of the first 5-speed transmissions with a maximum torque. This transmission was developed for special vehicles with RWD and powerful engines with the capacity from 4.5 liters.

In terms of design, this transmission is related to 5HP24 (intended for a bit lower torque) and has some common spare parts (such as seals and solenoids) with a legendary 5HP19. Compared to 2 abovementioned transmissions, ZF5HP30 has the reserve of structural integrity. This transmission was designed to become an "invincible" unit without obvious soft spots and a high safety degree in all components.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD		13	5,5	LT -71141

Technical issues and repair guidelines

The transmission requires a planned overhaul after running well beyond 300 thousand kilometers (under the condition of normal operation and timely fluid change). The transmission reassembly is performed together with filter replacement, torque converter repair and replacement of rubber and paper gaskets. The drum (Forw/Rev. Clutch A+C) is considered to be a soft spot of this transmission (aluminum teeth get cu

All solenoids are replaced with the purpose of ensuring reliability, because their resource usually comes to an end after 7-10 years of exploitation together with wear-out of the torque converter. The worn-out torque converter clutch is the main source of premature ageing of solenoids and as a consequence – problems with pressure in packages. In general, this transmission is quite reliable with a high safety reserve on transmission elements.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Aston-Martin	DB7	00-04	5 SP RWD	V12 5.9L
BMW	5-SERIES	91-03	5 SP RWD	V8 3.5L 4.4L
BMW	7-SERIES	95-01	5 SP RWD	V8 3.5L 4.4L V12 5.4L
RollsRoyce	ARNAGE/SILVER SERAPH	00-03	5 SP R/4WD	V8 4.4L V12 5.4L

How to repair this transmission (Videos)

Oil Change Part 1

Oil Change Part 2

Valve Body disassembly

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual 5HP30
pdf	www.at-manuals.com	Spare parts catalog 5HP30

5HP18 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed ZF5HP18 transmission is related to 4-speed 4НР14 and 4HP22 units. It had been installed on RWD BMW of 3-rd,5-th and 7-th series with 2-3 liter engines since 1991 up to 1999. The ZF5HP18 unit is a predecessor of famous ZF 5HP19 for a bit less powerful engines (310 Nm in comparison with 325 Nm in 5HP19). This well-designed gear shifting solution with high reserve on transmission components, which served as a prototype of the ZF 5HP19 solution.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD		10,5	5-5,5	LT -71141

Technical issues and repair guidelines

This transmission endures exploitation with contaminated fluid, fluid shortage, and operation without a warm-up. This transmission will fully serve the service life, if you monitor the ATF quality and timely replace the metal-plastic filter with a felt membrane. This transmission can operate with different types of oil (works well with oils like Dexron III).Too rapid ATF contamination is a signal of gaskets wear-out and trigged by it risk of oil starvation on fiction components.

To perform a typical overhaul with reassembly of worn-out gaskets and rings repair specialists usually order the Overhaul kit for this transmission.The most vivid soft spot of the 5HP18 unit is the clutch package F – the first one to get out of order because of ATF shortage and burnt frictions.The cause of this problem is related to design of the drum F bushing with a sealing, which become the source of leakages leading to oil starvation and bushing cranking.If the abovementioned problem stays neglected, then the clutch drum F with a piston gets burnt together with frictions. This problem is solved by the bushing replacement with the bearing.

The oil pump is one more typical part to be worn-out in “old” transmission hard parts under the condition of long-term exploitation with worn-out torque converter and pump bushing.The valve body is a long-running and maintainable unit.

The pressure solenoid (EPC) is a main part to be replaced or repaired among electrical components.Shifting solenoids are similar to solenoids used in the 4HP18 unit and they serve for a long period of time. EPC solenoids are the first to get out of order, then comes the turn of the TCC solenoid. In all other respects, the resource of this transmission is compatible with the resource of the whole car.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
BMW	3-SERIES	0	5 SP RWD	L6 2.5L 2.8L
BMW	5-SERIES	93-95	5 SP RWD	V8 3.0L
BMW	7-SERIES	0	5 SP RWD	L6 2.8L
BMW	M3	95-98	5 SP RWD	L6 3.0L 3.2L

How to repair this transmission (Videos)

Complete Tear Down

5HP18 Clutch Rebuild

Valve Body DIY

Valve Body DIY Part 2

G Clutch & Spring Damage

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual 5HP18
web	www.at-manuals.com	Scheme 5HP18

5EAT Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed RWD transmission 5EAT was designed in 2003 by Jatco on commission from Subaru for popular models Tribeca, Impreza, Outback, Legacy on a constructive basis of Jatco JR507E , reengineered for the engine room of Subaru.

Since 2005, the 5EAT unit has been operating on LEGACY model equipped with engines having the capacity from 2 to 3.6 liters. Later this transmission was paired with 3-liter engines Н6 on American models of Tribeca and Outback. The Impreza model for the Japanese market was also equipped with this transmission.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	AWD	350	10	5,6	Subaru ATF HP

Technical issues and repair guidelines

This transmission allows accelerating as DSG by means of the torque converter lock-up slipping, leading to rapid fluid contamination and resulting in damage of the friction lock-up. Consequently solenoids wear out and the valve body gets clogged.Therefore, manufacturers of automatic transmissions assume that it is better to change the fluid with filter after covering 80 thousand kilometers (depending on the driving style) and change it the next time when oil transparency is not good enough. After 120-150 thousand kilometers, it is necessary to check for the presence of metal grit in the pan.

Oil change and first overhauls usually require order of the plastic filter with felt "accordion" connection.Specialists install the external main filter sequentially to metal coarse mesh filter. The filter is located outside of the transmission and access to it is maximally facilitated. The main filter helps to keep the oil clean and reduces the wear of the friction components and aging of solenoids. These measures are recommended for all old transmissions, which have a regular filter with a metal mesh.The repair kit of gaskets and seals/Overhaul kit is usually ordered with the kit of friction components.

There are two types of solenoids which are usually get replaced: solenoid in the Direct package (this solenoid operates more intensively than others) and solenoid of the second type with a cover plate, and the problem is specified by the computer error (The problem may lie in the spooling burn-out resulting in improper gear shifting or wear-out of the valve mechanical part.). The list of typical problems in the 5ЕАТ unit also includes solenoids and the speed sensor overheating and clogging with dirt and metal chips from the torque converter.

The list of soft spots for this transmission also include:

-Pump with bushing and seal.

- Shaft with a sun gear of an interaxle planetary gear for vehicles with engine capacity over 3-liters.

The design of the 5ЕАТ unit is similar to the construction of Jatco’s RE5R05. Many spare parts in these transmission units are interchangeable. But the valve body and solenoids are different.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Subaru	EXIGA	08-16	5 SP F/4WD	H4 2.0L
Subaru	IMPREZA	11-13	5 SP 4WD	H4 2.0L 2.5L
Subaru	LEGACY	03-14	5 SP 4WD	H4 2.5L H6 3.6L
Subaru	OUTBACK	09-14	5 SP 4WD	H6 3.6L
Subaru	TRIBECA	06-14	5 SP 4WD	H6 3.0L 3.6L

How to repair this transmission (Videos)

Subaru 5eat Valve Body

Instruction manuals and useful links

Link type	Source	Description
pdf	subarufanclub.cz	Technical data 5EAT
pdf	atsg.us	5EAT VALVE BODY ASSEMBLY
pdf	transmissionpartsus.com	Scheme 5EAT

4T80E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 4T80E was designed in 1993 together with 4.6 liter engine V8 Northstar for FWD Cadillac models. In 2004, this heavy and high-priced transmission was significantly updated and installed with the same engine on Buicks and Oldsmobiles.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	450	14,2	6,6	Dexron VI

Technical issues and repair guidelines

The owner of this rare transmission usually order only a 3-component filter. The overhaul generally consists in the valve body cleaning, the torque converter repair and gaskets replacement.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	LUCERNE	05-11	4 SP FWD	V8 4.6L
Cadillac	CONCOURS/SEVILLE	95	4 SP FWD	V8 4.6L
Cadillac	DEVILLE/SEVILLE/CONCOURS	96-05	4 SP FWD	V8 4.6L
Cadillac	DTS	05-11	4 SP FWD	V8 4.6L
Cadillac	ELDORADO	95-02	4 SP FWD	V8 4.6L
Cadillac	LIVERY/HEARSE/LIMO	97-01	4 SP FWD	V8 4.6L
Oldsmobile	AURORA	95-03	4 SP F/4WD	V8 4.0L

How to repair this transmission (Videos)

4T80E Teardown

4T80 transmision from cadillac 2003

4t80e trans side case bearing

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Sensors 4T80
pdf	www.at-manuals.com	Converter Update for GM’s 4T80E
web	www.at-manuals.com	Scheme 4T80e

4HP18 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission ZF 4HP18 (4HP18FLA Audi) was on SAAB 9000 (4HP18Q), Rover, Peugeout, Citroen. In 1989 this transmission was updated. Later, several more modifications were released. Presently, this transmission is mainly installed on FWD Audi 100 with engine capacity from 2.0 up to 3.0. Later this transmission was updated for AWD Audi 100 and Audi Quattro. ZF 4HP18 had been used on the abovementioned cars until 1994. This transmission competed with the legendary 097-01N transmission from Audi.The design of the 4HP18 unit became the foundation for the 5-speed 5HP18 and later for extremely popular 5HP19.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/AWD		9	4	LT 71141

Technical issues and repair guidelines

The majority of 4HP18 repair cases accounts for the transmission modification for Audi. But about the fifth part of all repair operations is related to Saab, Alfa 164, Lancia, Citroen, which have a round filter.

This transmission successfully operates with different types of fluid (LT 71141 as well as with Dexron 2 or 3). Synthetic oil is more efficient, therefore analogs of Dexton III are often used when performing complete fluid change.It is required to keep the fluid clean by means of regular and partial ATF change to reach the mileage of 300-400 thousand kilometers before the first overhaul. It is prohibited to use fluids of different colors, when performing partial oil change.

The repair kit of gaskets and seals is usually ordered when performing reassembly of this transmission. Overhaul and Precision kits are also quite popular. All compression rings and rubber elements of all burnt packages also get replaced. It is common to replace frictions of Forward and 3-4 packs.

This transmission is handed in for repair (that happens quite rare) with the complaint, typical for old transmissions: burnt clutch packages and brake bands. Common parts for replacement in this transmission are pump bushing and turbine shaft bushing. Vibrations turn down the compression ring located on support of the pump.The “cosmetic” overhaul of this transmission with worn-out torque converter sometimes is limited to the pump repair and its bushing with the pump seal replacement. Minor repair operations of electrical parts (decayed isolation and contacts) are performed without transmission removal by owners themselves.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	MONACO	90-92	4 SP FWD	V6 3.0L
Eagle	PREMIER	90-92	4 SP FWD	V6 3.0L

How to repair this transmission (Videos)

ZF4 HP18 Transmission: Part 1

ZF4 HP18 transmission. Part 2

How to replace ZF4-HP18 governor seals

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Application chart
web	www.at-manuals.com	Scheme

09G Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 09G (TF60-SN - according to Aisin Co classification) is the first 6-speed transmission which has been used since 2003 for virtually all FWD cars of Volkswagen and Audi family (A3, A4 and TT) with engine capacity from 1.4 up to 2.0 liters (Mini Cooper, Skoda Fabia, Polo)

The 09G is designed for torque up to 280 Nm.This solution is the successor of 5-speed AW55-50. It competes with the German transmission ZF 6HP19-/21 and considered to be more durable and relatively cheap in repair.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD	280	7	4	G 052 025 A2

Technical issues and repair guidelines

The 09K and 09M sub-modifications were released after testing and upgrade of the 09G transmission. They were used together with engines with the capacity equal up to 3.5 liters (TF-62SN -61SN, Passat, Superb, Transporter). Many other modifications of this transmission, which differ mainly in electric components and the valve body construction, can be encountered in the repair shops. Peculiarities of the TF60SN transmission are typical for most of 6-speed transmissions and are associated with fast ATF contamination by the friction lining of the torque converter which operates with slipping of the lockup clutch, and when the engine operates under unusually high temperature. The torque converter is rebuilt during each overhaul.

Typical repair procedures for the 09G (TF-61SN \TF-60SN) transmission

Typical overhaul of the 09G transmission involves reassembly and replacement of following spare parts:

A set of 4 problematic pistons consisting of a piston / retainer pair for a problematic package К2 (С2) and retainers of clutches K1 and K3 is almost always changed together with seals and gaskets (overhaul kit). It is recommended to replace friction clutches together when the К2 package burns out completely and the rest of friction linings are stained with burnt ATF
Abnormal operation of the TF60-SN valve body often manifests itself in problems with 4-5-6 speeds. Error codes - P0734, P0735 or P0729 signal that solenoids and valves of the valve body are worn / clogged. The solenoids are rebushed with the help of the Bushings Repair Kit.
The transmission pump is the next stage in the repair process. The axle deformation, surface damage and bushing cranking are caused by an uneven wear out of friction lining and related thereto vibrations. The tool kit of bushings (5 pieces) also gets replaced. The most deformed bushings are: bushings of sun gear, rear cover, pump, and package К3 (С3).

The typical malfunction can be described as follows:

1-st stage. The torque converter friction gets actuated with slippage starting from the 3-rd gear, without waiting for the levelling of the transmission and engine shaft RPM. The friction element gets damaged and contaminates ATF with hard and sticky powder.

2-nd stage. Plungers and valves get blocked and give less oil pressure to one of the packages, and as a result, worn parts have leakages, oil overflows, critical decrease of pressure in the clutch packs.

One of the most complicated cases is the wearout of the valve body and/or one of its irreplaceable components. Then it is required to change the entire valve body. Another reason the valve body failure is the replacement of solenoids which exhausted their performance potential. Preliminary, it is required to check the wiring and electrics contacts. It is rare that problems are caused by the shaft speed sensors ISS and OSS, they are cleaned and the ATF is washed off. The replacement of pump and semi-axle seals is also performed quite frequently.

The pump bushing (46.9x43.9x14.8) is replaced, if the wear-out reaches 0.10 mm. First of all, friction components and clutch steel discs K2 4-5-6 (C2) are examined for wear. Clearances in clutch packages affect the quality of switching and hard parts wear-out. It is required to change the Piston К2 (C2) and the retainer. The retainer K1 is also replaced quite frequently. The cause of this problem is solved by replacing the repair clutch of the rear cover. It is more rarely that you have to replace spare parts of the K3 package. In many cases, the clutch drum wear-out leads to some kicks (impact) while shifting gears. The factory clearance (gap) is 1.4 mm. When the clearance (gap) increases up to 1.8 mm, then kicks become noticeable. Such friction components are replaced to stop the wearout chain reaction.

Problems with the rear planetary gear are mainly explained by slipping of insufficiently lubricated bushings. The torque converter is one of the typical problems for 6-speed automatic transmissions. It works with a wide “slippage mode”. The pressure for blocking is provided not by simple electric valve, but by the PWM solenoid. This mode of operation increases the car efficiency, but enormously speeds up the process of wear-out for the torque converter friction lining.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	TT	03-06	6 SP F/4WD	L4 1.8L
Volkswagen	TOURAN	03-06	6 SP FWD	L4 1.6L 1.9L

How to repair this transmission (Videos)

09G Transmission Repair - Part-1

09G Transmission Repair Part-2

TF60SN solenoids fix recondition repair upgrade shift kit

Instruction manuals and useful links

Link type	Source	Description
pdf	media.cylex.com	6-speed automatic gearbox 09G Service
pdf	www.atra.com	Disassemble the Solenoids 09G
pdf	www.evosoft.dk	Design and Function Self-Study Program 09G
web	www.at-manuals.com	Solenoid/clutch application chart 09G
pdf	Sonnax	Valve Body Layout TF-60SN
pdf	Sonnax	Vacuum test AW TF-60SN, BMW 6F21WA, VW/AUDI 09G, 09K, 09M

JF506E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 09A \ 09B (according to Jatco - JF506E classification) was designed in 1999 by Jatco for the European market of FWD cars with engine up to 3.8l. The first budget version of this 5-speed automatic transmission is used in the cars as a reliable and unpretentious alternative to expensive the AW55-50 from Aisin and ZF 5HP19-24.

After several modifications, this transmission has been actively used in Nissan – as RE5F01A and in Mazda as JA5A-EL. Most of all, this transmission is found under the German name 09A \ 09B in VW, Audi and under the name JF506E - in the English Jaguar and Land Rover. American Ford tried to use this transmission for European Mondeo and Galaxy (as 5F31J). The Japanese had been installing this transmission until recently at American assembly plants of Nissan (Altima, Quest) and Mitsubishi (Eclipse, Galant). JF506E is mainly installed on English Jaguar X, Rover, Freelander, less often – on German Golf, Bora, Jetta and even less often on Portugese SEAT Alhambra and AUDI А3.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD	350	9	5	G 052 990

Technical issues and repair guidelines

The 09A\09B/JF506E filter with metal mesh is replaced during the transmission reassembly. The planned overhaul of older JF506E lies in replacement of worn-out rings and gaskets which are frequently exposed to leakages. The overhaul includes the assembly and replacement of the whole friction components kit. Kicks, pushes, and slipping in this transmission are considered to be the symptom of solenoids and valve body malfunction.

One of the reason for valve body malfunction is the damage (by contaminated ATF) of the channel and valve (TCС Pressure Regulator Valve) controlling torque converter blocking . Then goes a chain reaction related to fast ATF contamination by the torque converter clutch, and dirt starts damaging other channels and solenoid-operated valves. The whole solenoid kit (9 pcs) is usually replaced in the process of transmissions (which covered more than 200-300 tonne-kilometre) overhaul. Common spare parts for cosmetic repair are: pump seal and pump bush, which is identical for RE4F03A. The filter helps to preserve ATF clean and reduces friction units wear-out.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Volkswagen	BORA	00-05	5 SP F/4WD	L4 1.8L 1.9L L5 2.3L
Volkswagen	GOLF/GTI	00-07	5 SP FWD	L4 1.8L 1.9L L5 2.3L
Volkswagen	JETTA	02-08	5 SP F/4WD	L4 1.8L 1.9L DIESEL V6 2.8L
Volkswagen	SHARAN	00-10	5 SP F/4WD	L4 1.8L 1.9L V6 2.8L

How to repair this transmission (Videos)

09A Transmission - Teardown Inspection

Freelander Transmission

solenoid replacement

transmission N92 solenoid bolt fix

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Technical supplement JF506E
pdf	www.at-manuals.com	TransTec Manual JF506E
web	www.at-manuals.com	Solenoid application chart JF506E
pdf	drive.google.com	Repair manual Update Handbook ATSG JF506e

010 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Since 1975 this 3-speed automatic transmission VAG 010 (later in 1983, it was used as a prototype for the automatic transmissions 087 and 089) has been successfully operating on many FWD models of Volkswagen (CABRIOLET, GOLF, JETTA) and Audi (80, 100, 200, ... and 4000S) with engines from 1.6 to 2.2 liters and on all Audi models starting from simple Audi 80 up to Audi 5000S. One more rare modification of this transmission for RWD vehicles - "090" (VANAGON) was released in 1978.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD		6	3	Dexron III

Technical issues and repair guidelines

The most popular kit of spare parts for maintenance of this “invincible” transmission, which often comes to the repair shop with half million kilometers of mileage usually consists of:

- Kit of friction components

- Kit of gaskets and seals (Overhaul Kit)

- Full kit of spare parts, which includes all gaskets, seals, frictions and steel discs (MasterKit). Sometimes, repair specialists order a separate kit of steel discs.There is some difference between repair kits of gaskets and seals for Audi 087 and 089 models.

As for the replacement frequency, then come the following spare parts:

- pump and axle seals (included in the repair kit), which are replaced with a full kit of bushings, their wear-out causes vibrations (which damage seals) and oil pressure in packages gets lost (that leads to friction linings burning);

- Rubber-covered pistons with friction clutches of packages Forward or Direct;

- Brake band (Direct, High/ Reverse) is replaced when it is completely worn;

- Rebuilding of the torque converter with replacement of spare parts.

This automatic transmission is very simple and reliable, which is used by many specialists as a guidebook for learning trasnmission repair methods.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Volkswagen	CABRIOLET	85-92	3 SP FWD	L4 1.8L
Volkswagen	GOLF	85-92	3 SP FWD	L4 1.8L 2.0L
Volkswagen	JETTA	80-92	3 SP FWD	L4 1.6L 1.7L 1.8L

How to repair this transmission (Videos)

BUILDING A VW TRANSMISSION

010 AUTOMOTIVE AUTOMATIC TRANSMISSIONS – LAYOUT and OPERATION

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Type 010 3-Speed Diagnosis & Overhaul
pdf	www.at-manuals.com	Transmission breakdown illustration 010
pdf	sympatico.ca	010 troubleshooting guide
pdf	thesamba.com	Repair manual 010 transmission

BAXA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4- speed automatic transmissions BAXA had been installed in Honda Accord since 1998 until 2002 and in Acura with the engine capacity 2.3 liters since 1998 until 1999. The list of construction peculiarities of BAXA transmission includes: 6 solenoids, 2 pressure sensors, and lack of overrun clutches. The design concept of solenoids helps to manage the shift overlap for upshifts and downshifts.

Honda Accord; 98-00; L4 2.3L; Honda BAXA; ATF Capacity/Change: 6.4/6.1 2.9/2.7

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		6,1	2,7	Honda Z-1

Technical issues and repair guidelines

The list of commonly replaced spare parts in this transmission includes two typical problems: wear-out of clutches of the 2-nd gear and damage of bearings. With worn-out clutches the car can operate for quite a long time, but the damage of bearings leads to non-operability of all transmission units. Bearing chips easily get through filters and penetrate aluminum transmission parts, plastic ring gaskets, and literally “eat” transmission components. The differential bearing is damaged in most cases, and sometimes needle bearings on shafts.

Wear-out of the 2-nd gear has the following symptoms:

1. Slipping when switching on the 2-nd gear

2. Jolt when stopping the car

3. Experiencing a jolt when shifting from mode D to 2 (when the car is stopped with started engine and depressed brake pedal).

The wear-out of bearings is identified with the help of following signs:

1. The sound of transmission disappears when shifting gear in “Park” or “N” mode. This symptom indicates damage of needle bearings in shafts.

2. Slap noise in chassis when running over high spots on the road, a large clearance of the transmission driven shaft, oil leakages from seals of driving gears.

1. Regular change of ATF and installation of additional radiator cooling system can really help in extending the service life of BAXA transmission.

2. When first signs of the transmission malfunction are detected, it is required to dissemble transmission and replace clutches, ring gaskets, and bearings.

How to repair this transmission (Videos)

Part 1 Disassembly BAXA

Part 2 Disassembly BAXA

Part 3 Disassembly BAXA

BAXA Automatic Transmission Overhaul Part 1 Teardown

Overhaul Part 2 Reassembly

AXOD Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The history of 4-speed FWD AXOD / AXOD-E / AX4S transmission started in 1986 when Crown Victoria was very popular with the engine 4.6 liters and Ford came up with the idea to produce a new bestseller for vehicles of lower class – Ford Taurusс with the engine capacity equal to 3.0 liters.

This transmission can be considered as a model emulated by the whole world of automatic transmissions. The transmission identification is specified according to the shape of the oil pan and gaskets. The gasket was covered with rubber in 1999 for the AX4S, but the pan shape was the same.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	250	12,2	6,6	Mercon V

Technical issues and repair guidelines

This family of automatic transmissions didn’t have a strong reputation among transmission experts. The transmission had a lot of problems with shifting gears 1-2, required frequent ATF changes, and had a short resource before and after the overhaul.

It is assumed that design solutions on the torque converter for this transmission are not good enough. All updates intended for improving the comfort of driving and its cost efficiency led to the following consequences: the transmission started operating under harsh conditions in terms of ATF temperature and its contaminanation.

The overhaul usually consists of transmission reassembly with the repair kit of gaskets and seals "Overhaul kit". “Old” vehicles (and vehicles which get in repair services with burnt oil) require replacement of brake bands O.D. and Rear (for old models). Due to the oil pressure losses in the line, problems occur in the shaft and its bushings. Spare parts of packs Direct and Forward usually get burnt because of high rate of operation. The main problem is related to the transmission design. And it is recommended to solve this problem by installing additional transmission radiator and each year change the ATF and replace the filter.

How to repair this transmission (Videos)

AX4S Overheating

transmission problem

AX4S 4F50N No Forward Gears

Instruction manuals and useful links

Link type	Source	Description
pdf	drive.google.com	AXODE (AX4S) UPDATE HANDBOOK ATSG

ATX Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

ATX is a 3-speed automatic transmission manufactured by Ford within the period from 1981 until 1994. It was Ford's 1-st automatic gearbox designed for FWD and cross-mounted engine. The structural design of this transmission is not complicated, but very reliable. This gearbox has a lockup torque converter, but no overdrive gear.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD		5,6	3,2	Type H ATF /Dexron III/Mercon ATF

Technical issues and repair guidelines

ATX was mainly installed in Ford Taurus and Ford Escort models. This fully hydraulic transmission is rarely met in repair services. However, owners of ATX may have problems with gear shifting if the engine is not warmed up. But transmission repair specialists say that the reason of this issue lies in wear-out of plastic gears, which can be replaced without dismounting and disassembly of the transmission.

How to repair this transmission (Videos)

Ford Escort ATX Transmission Fluid Change

A618 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of 4-speed automatic transmissions "TorqueFlite" - A518 / A618, has been mainly installed on the rear-wheel drive trucks and vans produced by Dodge and Jeep since 1990. The A518 was modified to 46RH (retainer hydraulic) and later to 46RE (retainer electronic), while A618 was updated to 47RE and 48RE. The A618 transmission is considered to be a heavier-duty modification of A518. The driving torque of the A618 transmission is equal to 610 Nm.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	610	13,4	4,8	Mopar ATF+4

The design of the A518/A618 and 46RH / 46RE / 47RH / 47RE / 48RE transmissions is based on the same principle. All differences and modifications consist in the increased number of gears and addition of the torque converter and the block of solenoids.

Typical problems

Transmissions of this family were used by car manufacturers for three decades thanks to their easy maintenance and resistance to wear. Not complicated assembly of these transmissions simplifies their repair process. Early transmissions of this family rarely require any repair. The problem of spare parts replacement occurs in cars equipped with transmissions, which have solenoids and the valve body. These transmission components get out of order when the car mileage reaches 100 thousand kilometers. Such breakdowns result in expansive repair services, because damaged components should be replaced.

The most problematic areas in A518/A618:

- Central Support

- Retained (Governor) is usually rebuilt

- Direct Drum – exhausts its resource, but more often this component burns out because of a long-time operation with insufficient linear pressure

- Reverse Drum

- Frictional wheel-hub. Direct.

- The set of solenoids and sensors

Other seals, bushings, springs and bearings fail to function occasionally, due to peculiarities of the driving style and operation.

How to repair this transmission (Videos)

47rh tear down

Remanufactured Transmission

48RE Transmission Teardown Inspection

Dodge 47RE

CUMMINS 47RE TRANSMISSION REBUILD

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout 48RE
web	Sonnax	Dodge 48RE Hydraulic Features Revealed

A40D Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The legendary family of automatic transmissions А40D (А42, А43, А44, А45, A46) was developed by Aisin Warner and belongs to Toyota Group. They have been used since 1985 as a 3-speed transmission named as 03-55(А40), and since 1979 as a 4-speed transmission for RWD cars with the engine capacity from 1.6 up to 3 liters. The 4-speed gearbox has D letter in its name and an additional clutch "Overdrive" in the 4-speed in the design.This gearbox is mainly used in right-hand drive cars (Hiace, Liteace etc.) and in other Toyota RWD cars in Asia. The modification with some other valve body AW03-70 .../72 or AW371, AW372 was produced for other markets. This modification was installed on Suzuki, Mitsubishi, etc. The most popular models of this family in repair services A44DE, 46DE \F (Previa), A42DE, 43DE were updated and released in 2000. This transmission is an example of a standard structural design, which was widely used by ZF in 4HP22 and by American Ford in its A4LD. The design of almost all rear-driven gearboxes ensures uniform wear-out of all units and solid safety coefficient of gearbox components, therefore these gearboxes easily travel 500 thousand kilometers. Earlier the repair process mainly involved transmission replacement.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	230	6,3	4	Toyota T-IV

Technical issues and repair guidelines

Typical issues of the А40 transmission are mainly caused by the the unit's ageing:

- Damaged torque converter lockup clutch. The damage of the lockup frequently causes heavy vibrations, resulting in the seal damage, then leading to issues with the pump liner and the pump itself.

- Worn-out friction components in Direct- Forward and Reverse packs. Old cars usually require replacement of these frictions.

- Rubber elements become hard with time and overheating causes the wear of rings, leading to pressure supply deficiency in packages and burning of friction components.

Overhauls mainly include the transmission reassembly and cleaning procedures accompanied by spare parts replacement – namely, worn-out brake blocks, frictions and gaskets with seals. All friction components are usually replaced during the overhaul of transmissions in cars with high mileage and burnt oil.The second most commonly replaced component in this transmission is the Low reverse clutch. Major repairs of hard parts mainly take place when the pump bushing (and leaking seal) gets damaged by the torque converter lockup clutch.

How to repair this transmission (Videos)

A40 Series Transmission Parts Identification

A40 Series Transmission - Powerflow

A40 hydraulic overview

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual A43D
pdf	www.at-manuals.com	Repair manual A46DE
pdf	www.at-manuals.com	Scheme A40D
web	www.at-manuals.com	Clutch application A40
pdf	mitsubishi-motors	Repair manual V4AW2-3

A130 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In terms of design, the 3-speed automatic transmission A131L with hydraulic control belongs to the family of FWD transmissions (А140 -\240-\540). Almost all hardware and spare parts are interchangeable.

This automatic gearbox is a very rare “guest” in repair shops. This is partly thanks to the fact that this transmission is maintenance friendly, simple, trouble-free in operation and its service life is much longer than the lifespan of the most reliable car. Usually this transmission is installed on American Corollas.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD	150	6,3	2,4	Dexron VI

Technical issues and repair guidelines

Simple and robust design of the A130 unit with two “invincible” planetary gears and without solenoids gives no reason for visits to repair services.The overhaul of this gearbox takes place after impressive mileages and frequently involves the torque converter repair, replacement of seals and gaskets, and less frequently replacement of worn-out friction components and even less often – brake bands.

Car owners prefer to change the filter (possible to use a А140 filter) than cleaning it, therefore statistics related to selling of spare parts for this transmission is unimpressive. A new filter with a narrow slot scoop produced in 1990 was supposed to force auto owners to change filters.The most common spare parts that wear out in these gearboxes are the following: seals, gaskets, rubber elements that become hard, weakening spring, damaged Direct and Forward friction elements, worn-out brake band.

How to repair this transmission (Videos)

Service A131L

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

6T40E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of 6-speed automatic gearboxes of GM 6T30E, 6T40E, 6T45E "Hydra-Matic" is a state-of-the-art range of FWD gearboxes used on Buick and Chevrolet vehicles from 1.4 to 3.2 lit. The 6T45E found application on FWD and AWD vehicles.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD	250	8,2	4	Dexron VI

Technical issues and repair guidelines

These gearboxes can operate properly with spare parts of different quality. Standard repair kits of gaskets and seals produced by ATOC often ordered for repair of these gearboxes.In case of ATF overheating it is often required to change all pistons because the rubber gets hard under the influence of the temperature. The set of pistons consists of 5 pieces.

The transmission fluid for these gearboxes should be changed every 40-80 thousand kilometers and checked for opacity every visit to repair services taking into account short service life of solenoids and torque converters (TC) with slippages. In the course of each overhaul, TC is reassembled and the lock-up clutch is replaced, because its wear-out reduces the resource of solenoids.Leaking seal of the TC unit is a sign of possible issues with the pump bushing, which gets damaged by vibrations and wear-out of the TC lock-up.

The construction of this gearbox is conceptually the same with ZF of 6HP series and problems in these gearboxes are caused by the same factors:vibrations which damage bushings. Vibrations lead to situations when ATF leaks through worn-out bushings.This is one more present-day gearbox in which it is important to examine the quality and temperature of ATF. In situation of any apprehensions related to contaminated ATF – change the fluid for protecting the valve body. It is also recommended to keep a wary eye on symptoms of the pressure loss in the line after a long-term operation as well as check and clean the valve body with solenoids. The TC unit repair with replacement of friction discs is required in the situation of rapid ATF pollution and issues with the valve body (especially with the mileage higher than 130-150 thousand kilometers). Overloading with high torques and aggressive accelerations also may have a bad impact on this gearbox.

On the top of everything else, experts recommend to install additional transmission radiator for the whole 6Т range of transmissions. Cars with this transmission manufactured over the last years are adjusted in more cautious way and stop drivers from using the car with neglect to this good 6-speed gearbox, which is capable to compete with Jatco CVTs in terms of comfort.

How to repair this transmission (Videos)

Removing the bellhousing to install seals and a filter

6T40 Teardown

6T40 Series, no reverse

6T40 Valvebody

6T75-E Transmission - No Reverse

6T70 Teardown

6T70 Valvebody

6T75 TCM REPAIR

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme 6t40
pdf	www.at-manuals.com	Repair manual valve body 6t40
web	www.at-manuals.com	Solenoid identification 6t40
web	www.at-manuals.com	Stall test
pdf	Sonnax	Valve Body Layout 6T30 & 6T40 (Gen. 2), 6T45 (Gen. 2), 6T50 (Gen. 2)
pdf	Sonnax	Valve Body Layout GM Gen. 1 6T40, 6T45, 6T50
pdf	Sonnax	Vacuum Test Guide 6T45 (Gen. 2), 6T50 (Gen. 2), 6T30, 6T40 (Gen. 2)
pdf	Sonnax	Vacuum test valvebody 1st GEN. 6T40, 6T45, 6T50

4HP22 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission ZF 4HP22 was designed in the early 1980s for 2-3 liter diesel (rear-driven) car models. It has a "classic" engineering structure, ensuring not only high robustness, but also even wear-out of parts without obvious soft spots. The 4HP22 - 24 unit was used by all European automakers of high-priced and reliable cars: Audi, BMW, Jaguar etc. In terms of design, this transmission is similar to famous A4LD from Ford and A40-series from Toyota. The 4HP24 unit found application in 4WD models.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	400	9,3	4	LT 71141

Technical issues and repair guidelines

The difference between 4HP22 and 4HP24 modifications lies in frictions and steel discs in packages. The modification with the valve body (type Е9) and 4 solenoids is the most common in repair, while earlier series with 5-solenoids in the valve body are considered to be a rarity.The ZF 4HP24 unit is a fail-safe and massive transmission, constructed with the help of high-quality materials, ensuring enhanced safety margin.

Repair procedures

Friction components of the Forward package are the first to get burnt because of intensive operation. The percentage of hard parts replacement and seals (separately) is quite low only in the overhaul kit (repair kit). It is common to replace worn-out pump housing bushing (covers – 17 mm), and less frequently bushings (13 mm) with the pump gasket and pump seal in the 4HP22/24 unit suffering from oil starvation. Land Rover’s oil pump gets out of service early because of contaminated fluid and long-term operation with a faulty torque converter. It is required to perform the torque converter repair together with the abovementioned procedure.The improper operation of clogged or worn-out solenoids and valve body is named as the main reason of oil starvation causing burning of the package Forward.

The replacement of solenoids is a scheduled procedure for old cars using this transmission. The problem of a dirty valve body is usually explained by worn-out locking clutch of the torque converter. If there are some delays with gears shifting, kicks or slippage in ZF 4HP22 with mileages above 200 thousand kilometers, then it signals that springs and solenoids cannot handle the dirt from frictions falling on valves. The minor overhaul prolongs the resource of this transmission for many years. It is suggested that the average resource of ZF4HP22 (4HP24) before the overhaul can reach up to 300 thousand kilometers, but it depends on the driving style “aggressiveness”.

How to repair this transmission (Videos)

Service & Valve Body Recondition

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

BGHA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This family of 5-speed automatic transmissions Honda includes several sub-groups. A typical order for reassembly of 5-speed automatic transmission in old cars includes the following:

- Repair kit of gaskets and seals
-Kit of friction components
- Filter
- Electrical parts and Low block

Spare parts for the 5-speed automatic transmission designed by Honda should be selected according to the VIN-code.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	AWD		7,9	3,3	Honda Z-1

Technical issues and repair guidelines

In many cases, the Low Hub one-way clutch gets out of order because of overloadings. It gets wedged and the sun gear breaks. High torque from 3-liter engine damages the rear drum of the 3-rd package (3rd Drum). The spring breaks, that causes damage to the entire unit. Specialists also replace piston, a thin spring holder, retaining ring. In addition a powerful engine damages rear bearings.EPC line pressure solenoids (which operate very intensively) get out of order because of ageing and overheating. Another soft spot of the valve body is the jar of accumulators, rubbing shafts with teflon rings that leads to the pressure loss.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Acura	MDX	01-02	5 SP 4WD	V6 3.5L

How to repair this transmission (Videos)

BGHA Transmission - Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout BVGA Honda/Acura 4/5 Speed
web	Sonnax	Keeping Cool While Investigating Mystery Honda Overheat
pdf	Sonnax	Honda/Acura 4/5 Speed Identification Guide
web	Sonnax	Overheated Honda Converters/740 Codes

M4VA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The first Honda CVT transmission named as M4VA (Multimatic) was designed in 1995 for Civic with engine 1.6 liters and had been installed on American models of Honda until 2000. In 2000 this CVT was slightly updated and renamed as MLYA, but after a short time a new modification under the name SLYA was released and installed not only on American Civic but also on Honda City. The modification SLYA didn’t have typical problems of the predecessor and this CVT had been produced from 2002 until 2005 for Civic with the engine 1.7 liters. To this day SLYA is installed on 1.5 liter Honda Fit.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	AWD		6,8	4,1	Honda Genuine CVT (VTF)

Technical issues and repair guidelines

The belt is the main spare part which specifies the lifespan of this gearbox. In terms of design, this gearbox is very similar to the RE0F06A equipped with a push belt. The chain gets strained and and side teeth wear down. Timely detected problems with the belt allow saving surfaces of shafts and only to replace the belt. As with all pushing belts, it is crucial to set the right direction of the belt during the assembly operation, otherwise the owner will soon have to order a new CVT.

The overhaul of this popular and rare (in repair) CVT is usually accompanied with order of the following spare parts:

- Filter cassette

- Filter in the pan

- Pan gasket

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	AIRWAVE	05-11	CVT F/4WD	L4 1.5L
Honda	CIVIC HX	96-00	CVT FWD	L4 1.6L
Honda	FIT	09-12	CVT FWD	L4 1.3L

JF613E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed transmission JF613E with transverse mounting was produced by Jatco in 2006 for FWD Mitsubishi cars with engine capacity from L4 2.0 to V6 3.5 liters. According to Jatco, this heavy-duty transmission can transmit the torque up to 330Nm. The JF613E unit competes with Aisin's TF80SC, but Jatco transmission is considered to be less complex and cheaper, and when taking into account parameters of reliability and endurance with American 6T45 and Korean A6MF1.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/4WD	330	7,6	5,5	DiaQueen ATF J3

Technical issues and repair guidelines

Transmission fluid is changed after travelling 50-60 thousand kilometers without waiting for scheduled replacement of worn-out spare parts (rings and bushings).The torque converter is repaired in the course of the overhaul. The overhaul also requires Kit of gaskets and seals, complete kit of frictions, and less often kit of steel discs.

The main source of problems for all modern 6-speed automatic transmissions is related to the valve body and solenoids.Settings of the JF613 control unit do not allow excessive loading of solenoids. This gearbox as well as Aisin's 4-speed transmissions use forced locking of the torque converter starting at the 4-th gear (that has a positive impact on the transmission durability). Thanks to this feature JF613 may be called "invincible".

“Active locking” and “auto-neutral” features implemented in JF613E are considered to be the pride of Jatco. Both options improve acceleration characteristics, fuel consumption, driving comfort, driving uphill, but at the expense of the friction lining locking wear-out in the torque converter, leading to quicker ATF contamination. Planned repair for this transmission is not complicated and it is required in case of high mileage. The repair helps to prolong service life of this transmission for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mitsubishi	DELICA D:5	12-16	6 SP 4WD	L4 2.2L
Mitsubishi	LANCER	07-16	6 SP FWD	L4 1.8L 2.0L
Mitsubishi	OUTLANDER	08-16	6 SP F/4WD	L4 2.2L 2.4L V6 3.0L
Mitsubishi	RVR	13-16	6 SP 4WD	L4 2.2L
Nissan/Datsun	MURANO	10-15	6 SP 4WD	L4 2.5L
Nissan/Datsun	PATHFINDER	14-16	6 SP 4WD	L4 2.3L V6 3.0L
Nissan/Datsun	QASHQAI / QASHQAI+2	07-13	6 SP F/4WD	L4 1.6L 2.0L
Nissan/Datsun	X-TRAIL	07-15	6 SP 4WD	L4 2.0L
Renault	ESPACE	07-16	6 SP FWD	L4 2.0L V6 3.5L
Renault	KOLEOS	08-16	6 SP F/4WD	L4 2.0L
Renault	LAGUNA	07-15	6 SP FWD	L4 2.0L V6 3.0L 3.5L
Renault	LATITUDE	10-16	6 SP FWD	L4 2.0L V6 3.0L
Renault	MEGANE	09-16	6 SP FWD	L4 2.0L
Renault	SCENIC	06-16	6 SP FWD	L4 2.0L
Samsung	QM5	07-16	6 SP F/4WD	L4 2.0L
Samsung	SM7	11-16	6 SP FWD	V6 2.5L 3.5L

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Solenoid application chart

JF011E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The RE0F10A (JF011E) transmission is a popular Jatco model of 2005 for FWD vehicles with engine capacity from 1.6 up to 2.5 l. This transmission is assumed to be a marvel among CVTs. JF011E is a genuine leader of CVTs with record-breaking productions. It is very popular thanks to its durability, comfort, easy maintenance in combination with a low price. This CVT unit is very maintenance-friendly. Well-timed rebuilding procedures with replacement of spare parts add 3-4 years of service life before the next overhaul.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD/AWD	7,4	4,5		CVT Fluid NS-2

Technical issues and repair guidelines

In the process of major repairs, it is required to change the friction clutch of the torque converter lock-up. CVTs produced after 2007 turn out to be reliable (for CVTs) under the condition of proper usage and operates for 150-200 thousand kilometers with a low number of visits to repair services. It is one of the most reliable CVTs around the globe. Common spare parts usually include belt, step-motor (stepper), shaft bearings.

Spare parts of the first priority include:

- seals of the pump, axle shafts (left and right)

- Pan gasket

The step-motor ("stepping" motor of the gear ratio adjustment). The electric drive regulates the space between cones and gear ratio of CVT. Early breakdown of the step-motor is related to the overheating or CVT resource exhaustion. This issue comes from the RE0F06A and it is typical for JF011.

One of the most common reasons for getting into repair services for this transmission is related to the oil pressure shortage connected with improper working of worn-out valve of the high-pressure pump. In many cases, it is required to replace 4 bearings of input and output shafts. The issue is caused by overheating and critical wear-out of the belt, forcing solenoids to apply maximum effort on pressing the belt to cones. One of the most popular spare parts for JF011 units is a metal push belt RE0F010А (Bosch). Timely replaced belt preserves the surface of cones.

Solenoids with exhausted resource are also common for replacement. Some solenoids are interchangeable with other Jatco CVTs. But there also can be some differences with CVTs of Mitsubishi and Dodge. Another typical problem for the RE0F10A (RE0F06A) unit is related to the depress valve. This problem leads to oil starvation in CVT units. In the pump, the valve is replaced by the new one of a larger size. The service life of this CVT and the car itself is estimated by wear-out of cones. Surfaces of cones are considered to be the most important resource of CVT. The price of new cones with replacement service sometimes is higher than the price of an “old” car.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Citroen	C-CROSSER	09-12	CVT F/4WD	L4 2.0L 2.4L
Citroen	RVR	12	CVT FWD	L4 1.8L
Dodge	CALIBER	06-12	CVT F/4WD	L4 2.0L 2.4L
Dongfeng	S15	11	CVT FWD	L4 2.0L
Mitsubishi	CX	10-11	CVT FWD	L4 1.8L 2.0L
Peugeot	4007	09-12	CVT F/4WD	L4 2.0L 2.4L
Suzuki	SX4	11-13	CVT FWD	L4 2.0L

How to repair this transmission (Videos)

Transmission RE0F10A JF011E teardown

RE0F10A JF011E F1CJA CVT2M Disassembly Teardown Analysis

CVT TRANSMISSION BALL TO PIN CONVERSION PART 1

CVT TRANSMISSION BALL TO PIN CONVERSION PART 2

TRANSMISSION BALL TO PIN CONVERSION PART 3

JF011E Valve Body Inspection

RE0F10A JF011E Fault P0868 & Removal for Overhaul

Coolant Contamination

Jatco CVT

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	An Overview and a Look at Power Flow
pdf	www.at-manuals.com	Electronic and Computer Control Systems
web	www.at-manuals.com	Transmission RE0F10A (JF011E) Stall Test
pdf	Sonnax	Valve Body Layout JF011E (RE0F10A)
web	Sonnax	Chasing Bearing Noise in the JF011E CVT
pdf	aamcoftp.com	Manual JF011e

FNR5 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission FNR5 (FS5A-EL - Mazda, 5F27E - Ford) was designed in 2004 on the basis of the 4-speed automatic transmission 4F27E. This unit has several new elements, some upgrades in the valve body and settings of the control block for better acceleration characteristics, fuel saving and increase of smoothness in gear shifting. Since 2005, this transmission has been installed on FWD Mazda 6 (3-8) and Ford Fusion with the engine capacity from 2.0 up to 2.5 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD	250	8	5	ATF-FZ

Technical issues and repair guidelines

A typical soft spot of this automatic transmission family lies in the combination Drum Reverse + Rear cover. Aggressive driving style leads to the Overdrive clutch burning. Another typical problem of the 4F27E transmission occurs in Mazda cars, namely, wear-out of the servo mechanism seat of the band Overdrive. This problem is caused by vibrations from operation of the worn-out drum brake band. This chain of malfunctions includes different minor problems like wearout of teflon rings located between this drum and the support of the cover, which are replaced during each overhaul even if these components have no indications of damage.

Valve bodies of this transmission for Mazda and Ford are different. The valve body for Mazda has two solenoids of the main pressure EPC (А and В). The most common problem of all present-day automatic transmissions is related to contaminated ATF clogging the valve body, that in chain order leads oil shortage in packages and burning of friction elements. Frictions in this transmission may serve quite reliably together with other spare parts and solenoids for 200 thousand kilometers and even more, under the condition of well-timed ATF change, filter replacement, and avoidance of frequent forced accelerations. The valve body requires standard cleaning and replacement of spare parts.

Traditionally, Mazda's torque converter quite early requires repair or replacement of worn-out friction lock -up simultaneously with cleaning of the valve body and replacement of the pressure solenoid. The lack of locking, unusually rapid contamination of ATF and leaks through the seal near the torque converter may be considered as the sign of repair necessity for the torque converter. Operation with the worn out torque converter leads to vibrations on the shaft of the oil pump and cranking of the pump bushing (at the first stage of wear). This problem also has a negative impact on the pump seal.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercury	MILAN	05-08	5 SP F/4WD	L4 2.3L

How to repair this transmission (Videos)

FNR5/4F27E Common Causes for Code P0741

FS5AEL/FNR5 Highlites

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Solenoid identification FNR5
web	www.at-manuals.com	Stall test FNR5

F5A51 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of front-wheel drive 5-speed automatic transmissions A5GF1, A5HF1 (F5A51) from Hyundai has been modified since 2005 on the basis of 4-speed predecessor F4A51 and installed on the range FWD and AWD vehicles of Kia (Sportage, Sorento...) and Hyundai (Sonata, Santa Fe, Opirus, Karens... ) for the entire range of engines from 2 up to 3.5 liters. Mitsubishi uses this transmission named as F5A51.0. This front drive family of transmissions is related to the rear drive V4A51. Parts are maximally unified and interchangeable.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD/4WD		8,4	3,5	SP III

Technical issues and repair guidelines

With regard to clutch packages this automatic transmission is well balanced. These packages work properly during their lifespan. Problems are mainly related to wear-out of seals leading to oil shortages and problems with transmission components.The pump assembly is also replaced under the condition of a long-term operation with worn-out torque converter clutch and subsequent vibrations. Contaminated oil speeds up ageing of the pump and bushing. The pump bushing and the seal are the first to get out of order because of above mentioned problem.

Worn-out bushings are repaired and replaced quite frequently. Then the list of parts to be replaced includes the drum with a sun gear and the brake band. As far as the electrics of this transmission is concerned, speed sensors of the input and output shafts are the first to reach the end of their service lifespan. Solenoids Shift are standardized in all valve bodies. These solenoids operate properly for quite a long time, Solenoid-electric controller EPC (VFS) is the first to get out of order because of high loads.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	EQUUS	00-08	5 SP FWD	V6 3.0L 3.5L
Hyundai	GRANDEUR XG	00-05	5 SP FWD	V6 2.5L 3.0L 3.5L
Hyundai	SANTA FE	00-06	5 SP F/4WD	V6 3.5L
Hyundai	XG	01-05	5 SP FWD	V6 3.0L 3.5L
KIA	AMANTI	04-05	5 SP FWD	V6 3.5L
KIA	CARNIVAL	00-05	5 SP FWD	V6 3.5L
KIA	GRAND CARNIVAL	04-10	5 SP FWD	V6 3.5L
KIA	OPIRUS	03-05	5 SP FWD	V6 2.7L 3.0L 3.5L
KIA	SEDONA	02-05	5 SP FWD	V6 3.5L
Mitsubishi	DIAMANTE	00-01	5 SP FWD	V6 2.5L

How to repair this transmission (Videos)

F5A51 Sprag Rotation

F5A51 Transmission, No Forward, Slips in Reverse

F5A5A,F5A51, Transmission Rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout F5A5A (F5A51), A5GF1, A5HF1 (F5A51)

F4A51 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission F4A51 from Mitsubishi company was developed in 1998. This transmission modification is intended for FWD and AWD vehicles with engine capacity from 1.3 up to 2,8 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/4WD		8,5	3,5	SP III

Technical issues and repair guidelines

This 4-speed automatic transmission has two modifications. The modification F4A51 was used cars with engines capacity from 1,3 up to 1,8 liters. The modification F4A52 was used for more powerful engines. In terms of design, these transmissions are similar, but at the same time some elements in one transmission are larger than parts in the other one. This automatic transmission was installed on Japanese cars Mitsubishi Galant, Lancer and Korean cars Hyundai Serato, Santa Fe and Sonata. Subsequently, the transmission found application in different American and Chinese mid-size cars. Later this transmission was upgraded and a maximum engine torque was increased. It should be emphasized, that the F4A42 unit gained a good reputation. Thanks to simplicity of its design, this transmission is notable for reliability and durability. Its not a surprise when after running 300.000 kilometers this transmission does not require the overhaul. However, the service lifespan of this transmission also depends on operating conditions and the driving style of the car owner. This transmission is very sensitive to abrupt accelerations and is mainly intended for operation in urban areas.

In order to simplify the repair procedure of the F4A52 system, it is required to use special repair kits, which help transmission specialists to fix any malfunctions. Pump and seals are the main soft spots in this transmission. In specific cases, problems may occur in the valve body. The valve body damage usually leads to expensive and time-consuming overhauls.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chery	DONGFANGZHIZI	03-14	4 SP FWD	L4 2.0L 2.4L
Chery	DONGFANGZIHIZI	12-13	4 SP FWD	L4 1.8L
Chery	EASTAR	08-16	4 SP FWD	L4 2.4L
Chery	TIGGO	05-16	4 SP F/4WD	L4 2.0L 2.4L
Chery	TIGGO / TIGGO 3	05-13	4 SP FWD	L4 2.0L 2.4L
Chrysler	SEBRING	01-05	4 SP FWD	V6 3.0L
Dodge	STRATUS	01-05	4 SP FWD	V6 3.0L
Hyundai	GRANDEUR XG	00-05	4 SP FWD	V6 2.5L
Hyundai	SANTA FE	01-06	4 SP F/4WD	L4 2.0L
Hyundai	SANTA FE	06-12	4 SP F/4WD	V6 2.7L
Hyundai	TRAJET XG	00-07	4 SP FWD	L4 2.0L V6 2.7L
Hyundai	TUCSON	04-09	4 SP F/4WD	L4 2.0L
Hyundai	XG	01-05	4 SP FWD	V6 2.5L
Inokom	SANTA FE	12-13	4 SP F/4WD	V6 2.7L
KIA	CARENS	06-11	4 SP FWD	L4 2.0L
KIA	CARNIVAL	00-14	4 SP FWD	V6 2.5L 2.7L
KIA	LOTZE	05-10	4 SP FWD	L4 2.0L
KIA	SPORTAGE	04-10	4 SP F/4WD	L4 2.0L V6 2.7L
Mitsubishi	CHARIOT GRANDIS	00-04	4 SP FWD	V6 3.0L
Mitsubishi	DIAMANTE	97-05	4 SP FWD	V6 2.5L 3.0L 3.5L
Mitsubishi	ECLIPSE	96-05	4 SP F/4WD	V6 3.0L
Mitsubishi	GALANT	99-07	4 SP F/4WD	V6 3.0L 3.8L
Mitsubishi	LANCER	09-15	4 SP FWD	L4 1.5L 1.6L 1.8L
Zhonghua	JUNJIE	06-15	4 SP FWD	L4 2.0L
Zhonghua	ZUNCHI	02-12	4 SP FWD	L4 2.0L 2.4L

How to repair this transmission (Videos)

F4A51 Teardown Inspection

F4A51 Highlights

F4A51 Transmission Planet Failure

Pump Leak Cracked

Pump Alignment

No Forward, Slips in Reverse

F4A41 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission F4A41 / F4A42 from Mitsubishi was designed in 1997 for FWD vehicles of the middle class with engines (1.3 - 2.8 lit.). This transmission was strongly influenced by Chrysler. In terms of design, this range of transmissions is more related to А604, then to KM series. The F4A41 unit is installed with engines 1.3 - 1.8 lit., updated modification F4A42 for engines 1.6 - 2.8 lit F4A41-42 has been used since 1999 on many well-known FWD cars of middle class with engine capacity about 2 lit. The W4A42 is a rare version on the basis of FWD automatic gearbox for 4WD light motor vehicles.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		7,8	3,8	SP III

Technical issues and repair guidelines

This Mitsubishi-Hyundai family of transmissions is frequently repaired. The distinction between F4A41 and F4A42 units lies in distinct quantity of frictions in packs, and consequently clutch drums of various capacity. The transmission reassembly commonly requires the kit of gaskets and seals, filters and complete kit of frictions. In old cars which went through the oil starvation, specialists change the entire kit of bushings together with usual procedures related to cleaning and reassembly.

In terms of design, the main soft spot of the F4A41 unit is the planetary gear Overdrive, where the needle bearer gets dyed when exposed to overloading. The rear planetary gear and a crown gear also get out of order. This planetary gear was repeatedly updated. In most cases, specialists replace burnt Overdrive package, frictions with steel and bearing discs. The valve body is one of the causes for burning of packages Underdrive and 2-nd Brake. The wearout and clogging of valves and solenoids leads to fluid shortages not only in these packs, but also in the TC unit. The valve body was repeatedly updated and now has modifications with 5 and 6 solenoids.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mitsubishi	CARISMA	95-03	4 SP FWD	L4 1.6L
Mitsubishi	DINGO	00-02	4 SP FWD	L4 1.3L 1.5L 1.8L
Mitsubishi	LANCER	12-13	4 SP FWD	L4 1.5L 1.6L 2.0L
Mitsubishi	LANCER	13-16	4 SP FWD	L4 1.6L
Mitsubishi	LIBERO VAN	00-02	4 SP FWD	L4 1.5L 2.0L
Mitsubishi	MIRAGE	98-03	4 SP FWD	L4 1.5L 1.6L

How to repair this transmission (Videos)

Part 1 - Teardown

Part 2 - Valvebody Rebuild

Part 3 - Clutch Assemblies and Seals Replacement

Part 4 -Reassembly

Part 5 FINALE -Reassembly

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout F4A41, F4A42, F4A51
web	Sonnax	F4A41/42/51 2-3 Flare or Flare/Bump

F4A33 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Thsi family of automatic transmissions is not complicated and quite reliable solutions based on the KM170. Thanks to their simplicity and durability these transmissions found application even on American cars Dodge, Plymouth. The 4-speed automatic transmission F4A33-1 was designed in 1991 for FWD cars of business class with engine capacities from 2.0 up to 3 liters. In most cases, it is installed on Hyundai Sonata. Mitsubishi installs its own version of this gearbox on models 3000 GT, DIAMANTE, ECLIPSE. For AWD cars the modification of this gearbox is named as W4A32/ W4A33.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		7,5	4,5	SP III

Technical issues and repair guidelines

Overhauls of these transmissions are triggered by two main reasons: fluid leakages via the damaged pump seal and issues with gear shifting. Generally, the leaking pump seal is a sign that the torque converter (TC) has been operating with a worn-out lock-up and vibrations for a long time leading to the damage of bushings and seal. Overhauls of these transmissions are usually performed when the car reaches high mileages and consist of reassembly and repair of the TC unit and filter replacement. Specialist always perform the repair of TC, valve body reassembly in half of the cases with check and change of solenoids and wiring. It is also required to replace brake bands if the transmission operates for a long time with burnt fluid. The long-term operation with worn-out torque converter may lead to the damage of seal and pump bushing. As a result, the pump bushing may be replaced. Vibrations may have a negative impact on the pump, therefore specialists have to order a complete kit of bushings for these transmissions.

Overdrive frictions are frequently replaced. Specialist assume that the main reason is related to poor design of an old O.D. piston. In new modifications, this piston has an updated configuration. Usually Direct-Forward ffrictions wear out because they are highly loaded. Solenoids are quite reliable, but when problems occur they are mainly caused by circuits of solenoids (solution –cleaning of contacts). The design of this gearbox is similar to the KM170. After proper reassembly, these gearboxes easily operate for several years until the next overhaul.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	STEALTH	91-96	4 SP FWD	V6 3.0L
Eagle	TALON	91-98	4 SP FWD	L4 2.0L TURBO
Hyundai	SONATA	94-98	4 SP FWD	V6 3.0L
Mitsubishi	3000 GT	91-99	4 SP FWD	V6 3.0L
Mitsubishi	DIAMANTE	92-96	4 SP FWD	V6 3.0L
Mitsubishi	GALANT	94	4 SP FWD	L4 2.4L
Plymouth	LASER	91-94	4 SP FWD	L4 2.0L TURBO

How to repair this transmission (Videos)

DSM Transmission Tips- Volume 1

DSM Trans Tips Volume 2 - Pump 11 742 просмотра 53 1 ПОДЕЛИТЬСЯ

Trans Tips Volume 3

Instruction manuals and useful links

Link type	Source	Description
web	mitsipedia.info	F4A33 info
pdf	atdsm.com	AUTO TRANS OVERHAUL F4A33
pdf	at-manuals.com	Repair manual F4A33
pdf	at-manuals.com	Scheme F4A33
web	at-manuals.com	Solenoid identification F4A33

F3A Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 3-speed automatic transmission F3A was designed by Mazda for its top of the line FWD vehicle Mazda 626 in 1983, when 3-speed automatic transmissions were extremely popular.

This transmission turned out to be quite good in the ratio price\quality, and despite some vulnerabilities, after some adjustments it was used on Ford vehicles in the class up to 1.6 liters - Ford Festiva, Stylus, Aspire.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD	120	6,6	3	Dexron VI

Technical issues and repair guidelines

This transmission was also installed on Chevrolet Spectrum and Mazda started using this transmission in 1986 on the 323 model.Then GEO, Suzuki Swift, and Mercury had been using this transmission until 1995. Ford had been manufacturing a budgetary Aspire equipped with the F3A until 1997, when 3-speed automatic transmissions were ousted from the market. It’s a very rare case when the F3A transmission gets in repair services. Spare parts for repair of this transmission are only kits of gaskets and seals and kit of bushings. The open filter with a metal lath gets replaced quite rarely, in most cases it is just washed for reasons of economy.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	ASPIRE	94-97	3 SP FWD	L4 1.3L
Ford	FESTIVA	90-93	3 SP FWD	L4 1.6L
GEO	STORM	90-93	3 SP FWD	L4 1.6L 1.8L
Isuzu	STYLUS	91-93	3 SP FWD	L4 1.6L

CD4E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission CD4E has been used since 1994 on well-known FWD vehicles with engines 2.0 - 2.5 liters of Mazda such as 626, Tribute and MX6 (LA4A-EL). Ford used this transmission on the Probe, and later after some updates on Mondeo, Escape and Fiesta (named as the 4F44E according to a new Ford classification).This transmission became quite competitive according to the ratio price/quality and had been used until 2007 (was in production for 13 years).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	250	9,5	3,7	Mercon V

Technical issues and repair guidelines

Experts assume that the design of the CD4E transmission is not good enough for 3 liter vehicles and profitable for repair services. This is due to the fact that CD4E is installed on long-living and unique vehicles, and also that this transmission is repairable and after some minor repair it operates for a long time. It is considered to be an American version of the 5HP19 transmission (on BMW-Audi-VW).Each overhaul of this transmission is accompanied by replacement of the filter. The filter has a felt membrane. ATF is changed every 60 thousand kilometers. The electrical part in the CD4E is considered to be simple and reliable. In some cases, transmission specialists only have to replace worn out block of solenoids.

One of the most vulnerable and repairable components in this transmission is a double drum, (clutch basket) Forward/Direct (6 Cylinder). Friction components and steel discs of both drums get replaced in the process of the drum repair. It is recommended to check the bushing of this drum together with steel and cover plates. This bushing is the 1-st element to get worn-out and requires replacement to prevent vibrations and losses of oil pressure.

Another common problem is the pump shaft failure caused by overloads. The oil pump often gets out of order when metal pieces appear in gears. The rubber of pistons rapidly wears out because of oil starvation and overheating. The kit of bushings is commonly ordered for repair of the CD4E transmission. Worn-out bushings in this automatic transmission is the sign of oil shortages and abnormal dynamic loads. In terms of design, the Forward planetary gear is considered to be another soft spot of the CD4E transmission. This planetary gear cannot endure ultimate loads from the engine. The reason is related to the bearing failure.

Torque converters of the CD4E are quite sensitive for such engines. One of the most frequent problems is the wheel hub bushing wear-out. The problem is related to insufficient oil pressure, overloads and overheating. The torque converter preventive repair should be performed in the course of the first overhaul after travelling 130-150 thousand kilometers. One more issue characteristic to the “old” CD4E transmissions is related to wear-out of the differential “teeth”. It is advisable to check the differential condition during the overhaul and reassembly.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	CONTOUR	95-00	4 SP FWD	L4 2.0L V6 2.5L
Ford	ESCAPE	01-08	4 SP F/4WD	L4 2.0L 2.3L V6 3.0L
Ford	MONDEO	00-07	4 SP F/4WD	L4 2.0L
Ford	PROBE	94-97	4 SP FWD	L4 2.0L
Mazda	626	94-02	4 SP FWD	L4 2.0L V6 2.5L
Mazda	MX6	94-97	4 SP FWD	L4 2.0L V6 2.5L
Mazda	TRIBUTE	00-08	4 SP F/4WD	L4 2.0L 2.3L V6 3.0L
Mercury	COUGAR	99-02	4 SP FWD	L4 2.0L V6 2.5L
Mercury	MARINER	05-08	4 SP F/4WD	L4 2.3L V6 3.0L
Mercury	MYSTIQUE	95-00	4 SP FWD	L4 2.0L V6 2.5L

How to repair this transmission (Videos)

Teardown Inspection

CD4E Teardown Inspection

Rebuild Part 1 - Transmission Repair

Rebuild Part 2 - Transmission Repair

Rebuild Part 3 - Transmission Repair

CD4E Quick Tip

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme CD4E
web	www.at-manuals.com	Solenoid identification CD4E, LA4A-EL
web	www.at-manuals.com	Application chart CD4E, LA4A-EL
pdf	drive.google.com	Repair manual CD4E ATSG

BMXA Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Honda transmissions differ completely from the rest of automatic transmissions, because Honda does not use planetary gears. Honda transmissions are not complex in terms of design, have larger dimensions and as a result considered to be more robust. But automatic transmissions produced by Honda also have some vulnerabilities related to electronic gear shifting control: friction discs, solenoids, and the valve body.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		6	2,7	Honda Z-1

Technical issues and repair guidelines

The most well-known range of 4-speed 3-shaft transmissions M4TA - Honda (CR-V) with engines from 2 to 2.4 liters. Automatic transmissions Honda are notable for their simplicity and reliability. Because of this, many car owners neglect basic maintenance services such as ATF quality control and timely replacement of the filter. Subsequently it results in clogging of valves in the valve body and solenoids, oil starvation and rapid wear-out of sealing rings, frictions and bushings. 300-400 thousand kilometers is considered to be a standard mileage before the first overhaul for these Honda transmissions.

Repair procedures

The torque converter (TC) is the first component to be repaired in Honda automatic transmissions. A major repair with reassembly starts with change of transmission fluid and replacement of a metal filter. The main external filter is usually installed by specialists on old transmissions.The repair of this family of transmissions with the filter is performed with the help of ordered repair kit of gaskets and seals with friction elements and steel discs. Friction elements are frequently replaced separately and steel discs as a full kit. Masterkit is the fullest repair kit of friction elements and steel discs with kit of gaskets.

Honda friction components usually operate for a long time, but after exhausting an enormous resource of frictions (above 300 thousand kilometers) or when these elements are soaked with burnt oil, then the change of all frictions would be the best option.Worn-out switching solenoids of linear pressure and the clutch lock-up solenoid are commonly replaced during repair procedures. The design of solenoids includes anodized plate element, which is likely to wear. This component is changed after running over 200 thousand kilometers.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Honda	JAZZ	08-12	4 SP FWD	L4 1.5L
Honda	STREAM	02-06	4 SP F/4WD	L4 1.7L

How to repair this transmission (Videos)

Honda Bmxa Teardown

BMXA, Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	TransTec Manual
pdf	www.at-manuals.com	Scheme
pdf	drive.google.com	Transtec BMXA manual

DP0 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The French automaker PSA (Peugeot Citroen Association) in collaboration with Renault launched the mass-production of the 4-speed automatic transmission DP0 (also named as AL4) in 1999. The automatic transmission AL4 is intended for a FWD vehicles with engines from 1,4 up to 2 liters. The automatic transmission AL4-DP0 is a unique and successful solution of French engineers. The design of this transmission is very simple and well-balanced according to the principle «nothing extra».

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	210	8	4	LT 71141

Technical issues and repair guidelines

The DP0 unit has a heat exchanger for oil cooling. All transmissions with the heat exchanger operate at a temperature close to critical. In summer time, the DP0 regularly overheats and has some problems with the electrical components, namely with the valve body. It is a constructive peculiarity of many automatic transmissions with the heat exchanger. After running 80 thousand kilometers its up to the auto owner to preserve this transmission from overheating. Friction components contaminate ATF, the dirt settles in the heat exchanger (which also operates as a filter) and as a result after critical contamination of the heat exchanger the oil does not have time to cool in case of the hot weather. Therefore, the valve body (and solenoids) start operating improperly. The more contaminated becomes the fluid, the higher the operating temperature and the lower efficiency of the valve body.

The resource of this transmission before the overhaul (under the condition of careful and proper usage) may reach 150-200 thousand kilometers after well-timed repair procedures with reassembly and replacement of spare parts. After these procedures the transmsision resource may be prolonged up to 500 thousand kilometers.

Soft spots of PD0

EPC and TCC solenoids are the most frequently replaced components of the DP0 transmission. Worn bushings are also often replaced by transmission specialists. The wear-out of bushings leads to the following chain reaction: bushings start leaking, packages do not have enough oil and the computer forces the ЕРС solenoid to open the channel to the full cross section, the pump operates under maximum load and the EPC solenoid rapidly wears. The operation with fluid shortage has a bad impact on friction components of the corresponding package. The valve body is a typical area for repair. The valve body is very sensitive to overheating and contaminated ATF. Overheating changes the metal plate geometry, valves wedge and springs become overloaded until they break down.

Oil losses through worn-out joints lead to the pressure drop in the line, slipping and burning of friction components. The wear-out of one-sided friction discs occurs evenly, therefore all friction discs are replaced during the overhaul. Specialists recommend to replace Teflon rings of the rear cover. Brake bands (the pair F2 and F3) are replaced in the process of each overhaul of the transmission with burnt ATF. Servo pistons are replaced together with brake bands. The damaged pump cup (seal) is the most popular part for repair among seals and sealing strips. One of the most common problems takes place in the needle bearing located between the hub 570 and drum 554 in the Е2 package . The clutch package E2 (4th) is the most popular part for replacement among spare parts.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chery	A3	09-16	4 SP FWD	L4 1.8L 2.0L
Chery	A5	06-10	4 SP FWD	L4 2.0L
Chery	CHANCE	13	4 SP FWD	L4 2.0L
Chery	COWIN 3	10-16	4 SP FWD	L4 2.0L
Chery	DONGFANGZHIZI	06-14	4 SP FWD	L4 2.0L
Chery	DONGFANGZIHIZI	12-13	4 SP FWD	L4 2.0L
Chery	EASTAR A6	09-10	4 SP FWD	L4 2.0L
Chery	NICHE	13	4 SP FWD	L4 2.0L
Citroen	C2	07-13	4 SP FWD	L4 1.6L
Citroen	C3	06-16	4 SP FWD	L4 1.6L
Citroen	C3 PICASSO	11-16	4 SP FWD	L4 1.6L
Citroen	C4	04-16	4 SP FWD	L4 1.6L 2.0L
Citroen	C5	00-16	4 SP FWD	L4 1.7L 2.0L
Citroen	C-TRIOMPHE	06-13	4 SP FWD	L4 2.0L
Citroen	DS3	09-16	4 SP FWD	L4 1.6L
Citroen	ELYSEE	03-14	4 SP FWD	L4 1.6L
Citroen	EVASION	00-01	4 SP FWD	L4 2.0L
Citroen	FUKANG	05-08	4 SP FWD	L4 1.6L
Citroen	PALLAS	07-13	4 SP FWD	L4 2.0L
Citroen	XANTIA	00-01	4 SP FWD	L4 1.8L 2.0L V6 2.9L
Citroen	XM	0	4 SP FWD	L4 2.0L 2.1L V6 2.9L
Citroen	XSARA/XSARA PICASSO	00-11	4 SP FWD	L4 1.6L 1.8L 2.0L
KIA	206 BESTARI	06-09	4 SP FWD	L4 1.4L
Nissan/Datsun	PLATINA	02-10	4 SP FWD	L4 1.6L
Peugeot	2008	13-16	4 SP FWD	L4 1.6L
Peugeot	206	98-15	4 SP FWD	L4 1.6L
Peugeot	207	06-16	4 SP FWD	L4 1.6L
Peugeot	208	12-16	4 SP FWD	L4 1.6L
Peugeot	3008	12-14	4 SP FWD	L4 1.6L
Peugeot	306	00-02	4 SP FWD	L4 1.8L 2.0L
Peugeot	307	01-15	4 SP FWD	L4 1.6L
Peugeot	308	07-16	4 SP FWD	L4 1.6L 2.0L
Peugeot	405	99-15	4 SP FWD	L4 1.6L
Peugeot	406/406 COUPE	00-05	4 SP FWD	L4 1.7L 1.8L 2.0L
Peugeot	407	04-11	4 SP FWD	L4 2.0L
Peugeot	408	10-16	4 SP FWD	L4 1.6L 2.0L
Peugeot	806	01-02	4 SP FWD	L4 2.0L
Rely	V5	09-16	4 SP FWD	L4 2.0L
Renault	CLIO	98-16	4 SP FWD	L4 1.4L 1.6L 2.0L
Renault	ESPACE	01-03	4 SP FWD	L4 2.0L
Renault	KANGOO	97-16	4 SP FWD	L4 1.4L 1.5L 1.6L
Renault	LAGUNA	03-07	4 SP FWD	L4 1.8L 1.9L 2.0L
Renault	MEGANE	02-14	4 SP FWD	L4 1.4L 1.5L 1.6L 1.9L 2.0L
Renault	MODUS	04-12	4 SP FWD	L4 1.6L
Renault	SAFRANE	00-01	4 SP FWD	L4 2.0L 2.2L
Renault	SANDERO	11-15	4 SP FWD	L4 1.6L
Renault	SCENIC	00-11	4 SP FWD	L4 1.5L 1.6L 1.9L 2.0L
Renault	SYMBOL/THALIA	00-13	4 SP FWD	L4 1.4L 1.6L
Samsung	SM3	09-11	4 SP FWD	L4 1.5L

How to repair this transmission (Videos)

Al4 Gear box , changing Valves

DP0 and AL4 valve body

AL4(DP0) rebuild

AODE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission AOD had been installed on well-known Crown Victoria with 4.6 liter engine since 1980, it was in production for 15 years. In 1993 it was updated into electronic AOD-E version. After that, it was modified into the 4R70W (1995) without significant changes and was used until 2006. The last modification of this popular series named 4R75W was released in 2003.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		8,5	3,5	Mercon V

Technical issues and repair guidelines

This family of automatic transmissions rarely gets in repair services and mainly requires replacement of some spare parts. But it is not because these transmissions are extremely reliable and durabile, but on the contrary, once these transmissions get damaged by overheating, they should be replaced rather than rebuilt.

Typical problems of these automatic transmissions (from AOD-E to 4R70W) include the following: wear-out of seals and rings, that results in oil pressure drop in clutch packs, oil overheating caused by the pressure shortage, clogging of the valve body, wear-out of the brake band and backlash of servo pistons, wear-out of the torque converter locking and backlash of the pump shaft with wear-out of seals and bushings, ageing of rubber and plastic elements.

Owners of this automatic transmission have to change oil and filter every 30-50 thousand kilometers, perform the torque converter repair, install additional transmission cooling system, and when having the slightest suspicion regarding shortages in oil pressure, it is necessary to visit the nearest repair shop. A typical overhaul of the "old" AOED transmission, except spare parts, includes the following: Kit of gaskets and seals \ Overhaul kit. Since 2003, transmissions of the 4R70W/4R75E/W series mainly have been delivered to repair shops.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	MUSTANG	95	4 SP RWD	V6 3.8L V8 5.0L

How to repair this transmission (Videos)

4R75E Transmission Teardown Inspection

4R75-E Transmission Repair

4R75E

AODE 4R70W Class part 1 lesson 4

AODE 4R70W Class part 2 lesson 4

AODE 4R70W Class part 2 lesson 5

AODE 4R70W Class Part 2 Lesson 6

AODE 4R70W Class Part 2 Lesson 7

4R70W Valvebody Overhaul and Tips

4R70/4R75W EPC Changes

Loss of 4th Gear Concerns

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Vacuum test 4R70E, 4R70W, 4R75E, 4R75W, AODE
pdf	drive.google.com	Repair manual Ford AODE

AW5550SN Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission AW55-50SN was developed by Aisin specialists at the end of the last century as an exclusive 5-speed automatic transmission for non-Toyota FWD vehicles with engines from 2 up to 3 liters. After update of the valve body and computer settings, this transmission as AF23 and AF33 was installed on GM models: Daewoo-Chevrolet (Captiva, Epica, Laketti ...), Saab, Opel and American Saturn and Suzuki. The testing of this unique transmission was performed since 2000 on Volvo cars (on C70, both the 40, 70 and S60s and S80s).

Part of the design solutions for this tranmsission are adopted from its successful predecessor - the 4-speed AW50-40. The transmission was so successful that even its competitors installed AW55 for their popular cars, simultaneously releasing their RE5R05A (JR507E) (Nissan-Jatсo) and 5L40E / 5L50E (GM-Europe).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	FWD	330	7,1	3,5	Type T-IV

Technical issues and repair guidelines

The torque converter repair after running 200 thousand kilometers is a routine procedure. Repair kits of gaskets and seals for this transmission are produced by many manufacturers. Frictions are replaced by whole packages. Packages of clutches and brakes are designed in a fairly balanced manner and wear out at about the same time. The complete kit of frictions is also ordered when linings of remaining (unburned) clutches are soaked with burnt oil.The most popular parts for replacement are the pump seal and the pump cover bushing. The first problem occurs when operating in the oil starvation mode and with the wornout torque converter. Almost each overhaul is accompanied with the torque converter cutting and its subsequent rebuilding. The lock-up friction lining wears out quite rapidly causing many issues in the AW55-50.

There are many signs of the faulty valve body, but the reason for the majority of premature (before 150-200 thousand kilometers) problems of the mechanical components in this transmission lies in insufficient pressure of the ATF coming from the valve body. Dirt in the ATF and high temperatures, wear out and clog channels of valves and solenoids of the valve body. Worn-out areas are clogged with dirt and plungers get wedged, so the ATF does not reach clutch packages and the torque converter lock-up.The valve body repair and cleaning should be performed as early as possible (when you notice the first signs of improper operation) in order to avoid typical and fatal problem, namely the valve body housing wear-out. For rebuilding of transmission units in "old" cars, specialists usually order the kit of frictions, steel discs, and repair kit of gaskets and seals (overhaul kit). At the same time specialists replace the brake band (because friction linings are soaked with burnt oil). The pressure shortage from oil, coming from clogged valve body may have a negative impact on bushings. The pump cover bushing is the first to wear out. In rare cases planetary gear bushings are pressed out.

Mechanical elements of the AW55-50SN transmission are very reliable or even may be called “flawless”. The evidence of reliability lies in the factor, that for 90% cases of transmission components repair, specialists order only the repair kit of bushings. But if a driver frequently overloads the transmission, then repair specialists sometimes have to rebush or replace worn-out rear planetary gear.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	EQUINOX	04-09	5 SP F/4WD	V6 3.4L
Opel / Vauxhall	ANTARA	06-16	5 SP F/4WD	L4 2.0L 2.4L V6 3.2L
Opel / Vauxhall	SIGNUM	03-08	5 SP F/4WD	L4 2.2L V6 3.0L 3.2L
Opel / Vauxhall	VECTRA	02-09	5 SP F/4WD	L4 2.2L V6 3.0L 3.2L
Pontiac	TORRENT	04-09	5 SP F/4WD	V6 3.4L
Saturn	ION	03-04	5 SP FWD	L4 2.2L
Saturn	VUE	02-03	5 SP F/4WD	V6 3.0L
Suzuki	XL-7	04-08	5 SP F/4WD	V6 3.6L

How to repair this transmission (Videos)

AW55-51SN / RE5F22A Teardown Inspection

AW55-51SN / RE5F22A Solenoid Repair

AW55-51SN / RE5F22A Solenoid Repair PART 2

AW55 Solenoid Adjustment, Diagnosis and Repair

AW-55SN Linear Solenoid Repair

AW55-51SN / RE5F22A Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout AW5550SN
video	Sonnax	AW 55-50/51SN Solenoid Bracket Identification & Installation
web	Sonnax	AW 55-50/51SN Pressure Tap Locations
web	Sonnax	AW 55-50 Differences Between Manufacturers Part 2
web	Sonnax	AW 55-50 Differences Between Manufacturers Part 1

AW5040LE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed hydraulically controlled automatic gearbox AW50-40 produced by Aisin Warner was designed in the 90-s for well-known "family" vehicles of the middle class with 2-liter engine: Renault Laguna, Volvo (С70), Saab, Opel. This gearbox is also installed on KIA and Daewoo. This gearbox can be easily identified according to the pan form. According to GM classification, this gearbox is known as AF14 (AW50-40LE).

The AW50-40LE version has enlarged hubs, drums, overrunning clutches, planetary gears, in order to transmit higher torque. In 1998, the new modification AW50-42LE (AF22) was released in order to expand the usage of this gearbox for engines with the capacity up to 3.0 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	250	12,5	6	Type T-IV

Technical issues and repair guidelines

In addition to the filter replacement and torque converter rebuilding, overhauls usually require repair kit of gaskets and seals (Overhaul kit). Besides the repair kit of gaskets, specialists also order a complete kit of frictions. It is especially needed in situations when burnt ATF from Direct and Forward frictions reach easily wornout frictions of other packages.The complete repair kit Masterkit is frequently ordered for a full reassembly of this tranmsission.

Typical repair areas in AF17 - AF22 (AW50-40, AW 50-42)

This gearbox is quite sensitive to ATF cleanness and as the filter is replaced in case of the gearbox disassembly, then old cars are provided with a cooling line of the magistral main filter. Typical problem of old AW50-40 components include the following: drum (Forwad/Direct) – wear-out of the fitting area, cracks in the welding joint area. This problem leads to burning of frictions and steel discs of this drum. Forward and Direct packages are replaced more frequently than others. Steel discs also get burnt in the abovementioned packages.The brake band is another component which is replaced in the process old cars overhauls in addition to replacement of spare parts and frictions. This band is also included in the list of recommended spare parts in case of burnt oil. Improper operation of the band in addition to kicks in the process of gears shifting also leads to rapid wearout of the drum Underdrive - С3.

The friction lining wears out unevenly leading to bushings beating and wear-out of pump units. Non-operating or worn-out torque converter lock-up leads to clogging, ageing and wearout of valves of the valve body and solenoids. If the gearbox operates for a long time with this problem, then shafts and pump get overheated, operate without oil, and as a result of vibrations overheat and damage bushings.Seals of the pump and semi-axles are replaced during each visit to repair services. If the problem with leaking seals and damaged bushing is neglected, then the whole pump is replaced. A common reason of all issues related to the oil pressure loss lies in malfunction and contamination of the valve body or solenoids. Usually this problem is related to large wear particles in ATF and the faulty torque converter.

Specialists like this gearbox for its reliability and simplicity. It operates during the whole lifespan of the car in which this gearbox is installed. But it is required to monitor the oil level and its cleanness, otherwise negligence may lead to pressure losses in the line and wear-out of bushings, spare parts and damage of bearings, that results in the necessity to perform the overhaul.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Opel / Vauxhall	ASTRA	00-04	4 SP FWD	L4 2.0L 2.2L
Opel / Vauxhall	VECTRA	00-02	4 SP FWD	L4 1.8L 2.0L 2.2L V6 2.5L 2.6L
Opel / Vauxhall	ZAFIRA	99-14	4 SP FWD	L4 2.0L 2.2L
Suzuki	SX4	06-12	4 SP FWD	L4 2.0L

AW6040LE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission AW60-40LE was designed by Aisin Warner in 1995 for FWD vehicles (Suzuki, Opel, Daihatsu, Fiat) equipped with engines up to 1.6 liters. After testing on Suzuki Estima, this transmission was widely installed on numerous models of different brands. According to GM classification AW6040LE is known as AF13.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	180	7,5	3,5	Type T-IV

Technical issues and repair guidelines

The worn-out torque converter lock-up requires repair after 200-300 thousand kilometers (depending on the driving style).

In addition to the filter, during the overhaul transmission specialists usually order the following:

-Repair kit of gaskets and seals

- Complete kit of fricion plates

-For the reassembly procedure specialists also order the kit of steel discs

In many cases, the main problem lies in two burned clutch packages: Forward and Package 3-4 (friction clutches and steel discs of packages Forward and 3-4).The brake band is ordered together with the kit of friction clutches. When the burnt oil comes to the friction linings, they start operating with noticeable jerks or slippages. The kit of 4 plastic washers of supporting bearings is replaced during the overhaul of ageing transmission.With regard to electrics, typical problems occur in valve bodies. Valve body units should be reassembled and cleaned in the process of each overhaul. Transmission repair specialists also should replace the gaskets.

The solenoid “shift” (gear shifting) is frequently replaced because of the end of service lifespan. The solenoid of the torque converter lock-up is also often replaced. Together with two above mentioned solenoids specialists replace the solenoid-electric controller EPC/SLT (main pressure).The reason for premature wear-out is assumed to be a long-time operation in contaminated and overheated oil with the worn-out torque converter lock-up.

The valve body usually is quite durable, but aggressive accelerations and driving with worn-out friction clutches may bring closer the replacement time. If there is smell of burning oil, then in most cases the problem lies in packages the Forward and 3-4.

Generally, the family of automatic transmissions AW60-40LE is considered to be maintenance-friendly as the majority of 4-speed Aisin transmissions. Thus, after the diagnostics and replacement of all worn-out parts it can operate for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Opel / Vauxhall	ASTRA	00-04	4 SP FWD	L4 1.4L 1.6L
Opel / Vauxhall	TIGRA	0	4 SP FWD	L4 1.4L
Suzuki	AERIO	02-07	4 SP F/4WD	L4 1.5L
Suzuki	CULTUS	00-03	4 SP FWD	L4 1.5L 1.8L
Suzuki	ESTEEM	95-02	4 SP FWD	L4 1.6L

How to repair this transmission (Videos)

AW 60-40LE

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Vacuum test AW 60-41SN

A960E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission А960Е with longitudinal positioning was designed in 2005 by Aisin Co for rear-driven Lexus cars (sedans GS300, IS250 and IS300) with 2.5-3 liters. It also operates on right-hand Toyota MARK X. This transmission is developed on the principle of modules on the basis of the 5-speed A750 transmission together with 6-speed A761, but intended for a lower torque (190-300 Nm). The main competitor of this transmission is ZF6HP19-21. According to Aisin Co classification, this transmission for Lexus can be named TB-65SN.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD	314	8,5	4,1	Toyota WS

Technical issues and repair guidelines

Frequently used sports mode of this transmission quickly leads to the wear-out of the torque converter friction and fluid contamination. If the piston friction turns out to be worn-out, then some glue components reach the fluid, that makes some instant negative impact on the valve body functionality. Contrary to the 6НР19 unit with the torque converter having several double-sided frictions for the slippery mode, the A960E transmission has a single friction glued to the piston, that requires monitoring of the wear-out and when having any suspicions related to lack of the torque converter lockup, therefore well-timed diagnostics and spare parts replacement procedures should be implemented.

Typical overhaul of А960Е requires replacement of the following parts:

- Kit of gaskets and seals, without pistons.

After burning of frictions they are all replaced with rubber seals. The contaminated fluid leads to wear-out of teflon rings. If these rings wear out, they start contaminating transmission fluid.

- Kit of frictions, which are replaced in most cases.

- Kit of steel discs which together with friction discs and repair kit of gaskets represents the complete repair kit (Masterkit).

Complete and timely replacement of spare parts in this durable transmission adds up to 70% of increased resource before the overhaul.

- The pan gasket is ordered each time when changing the ATF and removing the pan for the filter replacement.

The valve body repair with replacement of solenoids always implies the torque converter rebuilding. The torque converter spare parts are the first to exhaust their resource.One more problem that may be caused by vibrations from worn-out friction of the lock-up mechanism that damages the pump seal and bushing itself. The typical soft point of this transmission is the oil pump unit with leaking seal, and if it is neglected the problem spreads to the pump bushing. Further driving without timely repair of the torque converter leads to the loss of the pump itself. It is often accompanied by wear-out of the torque converter lockup solenoid.

Electrics in А960

The rebuilding of this old А960 unit includes the replacement of the linear solenoids. Selection of solenoids for the А960 unit is performed in accordance with VIN-code of the car. The peculiar feature of this reliable 6-speed automatic transmission is that the driver does not receive any noticeable signals related to the necessity to replace worn-out spare parts (the torque converter friction and solenoids which can not endure aggressive accelerations with the "slipping mode" of the torque converter clutch).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	GS	05-12	6 SP RWD	V6 3.0L
LEXUS	IS	05-12	6 SP R/4WD	V6 2.5L 3.0L

How to repair this transmission (Videos)

LEXUS IS 250 repair transmission A960E

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Solenoid identification A960E
pdf	www.at-manuals.com	Repair manual A960E
web	www.at-manuals.com	Stall test A960E
web	www.at-manuals.com	Pockets A960E
pdf	Sonnax	Valve Body A960E
web	Sonnax	Diagnosing Solenoid Performance Faults in A960

A6LF1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission A6LF1 is a part of 6-speed transmissions family (A6LF2/3, A6GF1, A6MF1 /2) produced by Hyundai. This transmission is an expensive and comfortable alternative to the 5-speed automatic transmissions A5HF1 (A5GF1). These transmissions had been tested since 2009 on a limited series of Hyundai Avante HD\MD and after 2-3 years of modifications were installed on luxury FWD and AWD cars Hyundai (Sonata, Opirus...) and Kia models with engine capacity from 1.4 up to 3.8 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/4WD	323	7,8	4	SP-IV

Technical issues and repair guidelines

Aggressive accelerations and critical overheats may lead to replacement of rings and valve body gaskets. After covering over 150 thousand kilometers replacement of the whole repair kit is considered to be a routine procedure. The aim of this measure intended for protecting solenoids which have to deal with higher loads caused by increasing oil leakages through sealings. The main signs of the problem are the following: wear-out of the torque converter lock-up, rapidly contaminating transmission fluid, and issues with gear shifting. The valve body disassembly usually indicates critical contamination and sticking of valves.

Insufficient oil pressure (caused by problems with the valve body or leaks of ATF through rings, jointing edges and as a result wear-out of solenoid valves) in most cases leads to burning of friction elements with Overdrive and Underdrive discs, but often drivers neglect this problem, resulting in replacement of all friction clutches and steel discs which operated in burnt ATF. Contaminated ATF from this package damages corresponding valves and solenoids of the valve body.

The vulnerability of the A6MF1/2 transmissions resides in burning of clutches 3-5\R and 2-6. For replacement of these burning packages, Hyundai released the kit of "Power Pack" friction elements with steel and bearing discs.The Overdrive is also frequently replaced by repair specialists. The problem is explained by overloads caused by contaminated fluid, resulting in wear-out of teflon rings on the rear cover and pressure losses in packages.A typical problem for Hyundai differentials is related to damage of splineways of the differential body under the condition of longtime and frequent wheels slippages. During the first years of testing, the main problem lies in the valve body and solenoids (problem identical to ZF transmission ZF6HP from which the valve body operation principle was adopted).

The most failure-prone solenoids are the following:

1. EPC solenoid

2. TCC solenoid.

3. Shifting solenoids

Another frequent problem for this transmission (as well as for other 6-speed automatic transmissions) is related to the torque converter clutch wear-out. The more often drivers use aggressive accelerations, the closer this transmission to the repair shop.

The valve body may be considered a soft spot in the electrical part of the A6MF2 \LF2 transmission. As in all 6-speed automatic transmissions, the A6LF1 valve body is very sensitive to overheating and contaminated ATF, which first of all may be provoked by wear-out of the torque converter friction and clutch packages and in chain order lead to (pressure shortage from solenoids and the valve body) more rapid wear-out of frictions in packages of clutch and braking. Problems at the early stage are usually solved by repair and cleaning of the valve body and solenoids, opening of the torque converter for replacement of spare parts. In more complex repair cases, transmission specialists have to repalce solenoids.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	AZERA	11	6 SP FWD	V6 3.3L
Hyundai	GRANDEUR	11-16	6 SP FWD	V6 3.0L
Hyundai	MAXCRUZ	13-16	6 SP F/4WD	V6 3.3L
Hyundai	SANTA FE	12-16	6 SP 4WD	L4 2.0L V6 3.3L
Hyundai	TUCSON	10-16	6 SP FWD	L4 2.0L
Inokom	TUCSON	15-16	6 SP FWD	L4 2.0L
KIA	CARNIVAL	14-16	6 SP FWD	V6 3.3L
KIA	K7	16	6 SP FWD	V6 3.0L
KIA	OPIRUS	11-15	6 SP FWD	V6 3.0L
KIA	OPTIMA	13-16	6 SP FWD	L4 2.0L
KIA	SORENTO	14-16	6 SP F/4WD	V6 3.3L

How to repair this transmission (Videos)

Sportage A6lf1

A6LF1/2/3

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme A6LF1
pdf	Sonnax	Valve Body Layout A6GF1, A6LF1/2/3, A6MF1/2

A650E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission А650Е with the langitudinal positioning has been installed since 1998 on RWD Lexus (as AW 35-51LS) and for some period of time on 4WD cars such as Land Cruisers and Hilux. This robust automatic transmission had been installed on the RWD and right-handed Toyota produced from 1998 until 2007. The А650Е unit replaced the first 5-speed transmission А350 which was the updated version of 340-series.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/4WD	430	8,9	3,8	Toyota Type T-IV

Technical issues and repair guidelines

The А650Е unit is a rare “guest” in repair shops. Partly this is due to the fact that this transmission was so-called “pioneer” used for testing new technologies of linear solenoids, increased temperatures and slipping of the torque converter lockup, and partly because all Aisin products with longitudinal positioning are traditionally quite durable. Many units and spare parts from А340 can be used in the А650Е modification.

It is a very rare case when all gaskets and seals from the overhaul kit and friction components in 2nd Brake package are changed in the dry-operating А650Е transmission.Occasionally, long-time operation of the transmission with a leaking seal leads to necessity of the pump and pump bushing replacement. This problem is caused by the wear-out of the torque converter friction, where spare parts are untimely replaced. This automatic transmission was replaced by 5-6-speed А750Е and А761Е.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	GS	98-05	5 SP RWD	V6 3.0L V8 4.0L 4.3L
LEXUS	IS	00-05	5 SP RWD	V6 3.0L
LEXUS	LS	98-03	5 SP RWD	V8 4.0L 4.3L
LEXUS	SC	98-05	5 SP RWD	V8 4.0L 4.3L
Toyota	ALTEZZA/ALTEZZA GITA	00-05	5 SP R/4WD	L4 2.0L V6 2.5L 3.0L
Toyota	ARISTO	00-04	5 SP RWD	V6 3.0L V8 4.3L
Toyota	BREVIS	01-07	5 SP RWD	V6 2.5L 3.0L
Toyota	CELSIOR	00-03	5 SP RWD	V8 4.3L
Toyota	CENTURY	97-16	5 SP RWD	V12 5.0L
Toyota	CENTURY	00-04	5 SP RWD	V12 5.0L
Toyota	CHASER	00-01	5 SP RWD	V6 2.5L
Toyota	CRESTA	00-01	5 SP RWD	V6 2.5L
Toyota	HILUX	00-05	5 SP R/4WD	V6 3.4L
Toyota	LAND CRUISER	00-02	5 SP 4WD	V6 3.4L
Toyota	MARK II	00-04	5 SP RWD	L4 2.0L 2.2L V6 2.5L
Toyota	PROGRES	01-07	5 SP RWD	V6 2.5L 3.0L
Toyota	SOARER	01-05	5 SP RWD	V8 4.3L
Toyota	SUPRA	2	5 SP RWD	V6 3.0L
Toyota	VEROSSA	01-04	5 SP RWD	V6 2.0L 2.5L

How to repair this transmission (Videos)

Failure in depth tear down

Transmission Fluid Change

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Solenoid identification A650E
pdf	www.at-manuals.com	Scheme A650E
web	www.at-manuals.com	Stall test A650E
pdf	drive.google.com	A650E Repair manual
pdf	drive.google.com	A650E_A750EF_A761E manual

A760E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic transmission A761E, (A760E -F \Н) with longitudinal positioning is similar to the 5 speed А750 in terms of design. It has been tested since 2003 with 8-cylinder engines of Toyota Celsior and with Lexus LS430. This powerful 6-speed RWD transmission was produced in pair with economical А960, intended for lower torque (200-310 Nm). This automatic gearbox together with А761-А960 are direct competitors of ZF 6HP26 and 6HP19 units.

A760E is a basic modification for RWD units,

- A760F – for AWD SUVs of Toyota and Lexus,

- A760Н – is a rare modification for 4WD light motor vehicles.

- in 2006, the upgraded А761 unit was released. It is notable for perfect operational parameters of a new valve body and solenoids.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD/4WD	420	11	4	Toyota WS

Technical issues and repair guidelines

All rear-drive Aisin transmissions are distinguished by design reliability, especially those units which are installed on Lexus cars, therefore this transmission is rare in the repair service and there is no much information on the overhaul statistics. Problems of the А761 unit are related to already known issues with А750Е. These problems are caused the fluid overheating or its contamination by friction dust. Many experts consider А760 for rear-drive cars to be extremely durable as all Aisin automatic transmissions. Components of this transmission can operate properly for more than 300 thousand kilometers without overhaul, under the condition that they operate with comparatively clean oil.

Typical issues in A761

Commonly, together with spare parts repair specialists also replace the package of friction discs, burnt as a result of pressure shortage caused by clogging of the solenoid or valve body. All frictions are usually replaced in case of burnt transmission fluid. When we talk about the most problematic elements in first generations of the А750-А761 family, we should point out relative dependency of electrical components of this tranbsmission (valve body) from from the fluid condition and wear-out of the torque converter lockup. All problems with shifting are usually related to spoilt and worn-out valve body. Therefore, any diagnostics and rebuilding procedures start with testing and cleaning of the valve body and solenoids. All valve body problems start with worn-out elements of the torque converter. The torque converter is repaired as well.

Valve bodies for А750, А761 and А960 are identical from the outside. But the internal design, computer settings and solenoids (as well as their quantity) have been constantly modified during testing, therefore selection of solenoids for replacement (as well as valve body selection) is performed according to VIN-code. The number 8870 is displayed on plates of the А761 transmission.The valve body replacement for this unit is relatively rare in comparison with European manufacturers on similar automatics (722.6 and ZF-6HP26). Generally, reassembly and cleaning of the valve body and cleaning-replacement of solenoids are performed when repairing the А761 unit. First and foremost, repair specialists have to replace solenoids. These solenoids have the valve, receiving the main load from contaminated fluid coming from the torque converter. Each replacement procedure of solenoids is accompanied by the torque converter repair and replacement of the lock-up friction.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
LEXUS	LX	11	6 SP 4WD	V8 4.6L
Toyota	CELSIOR	03-06	6 SP RWD	V8 4.3L
Toyota	SEQUOIA	09-12	6 SP R/4WD	V8 4.6L

How to repair this transmission (Videos)

A750 A761 Introduction

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Manual A760E
pdf	www.at-manuals.com	Vacuum test valvebody A760E
pdf	www.at-manuals.com	Scheme A760E
pdf	Sonnax	Valve Body A760H
pdf	Sonnax	Vacuum test A760E/F/H, A761E
web	Sonnax	Diagnosing Solenoid Performance Faults in A761
web	Sonnax	Toyota A750E-A761E Identification Guide

A750E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This 5-speed automatic transmission А750Е\ F produced by Aisin Warner has been used since 2002 for powerful rear- and full-drive SUVs Land Cruiser, 4Runner and Lexus. The А750F (4WD) is the most frequently repaired transmission mated to engines with capacity equal to 4.7 liters. The А750 transmission replaced the 5-speed А650Е from the previous generation and “invincible” А340 series. In terms of design, this transmission is similar to 6-speed А761 and А960 units. The А750 modification can be paired with 1GR-FE (for lower torque) and 2UZ-FE engines in 4WD cars.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/4WD	485	12	4	Toyota T-IV

Technical issues and repair guidelines

This transmission has almost flawlessly matched gear ratio, tested cooling and ATF heating systems. The acceleration in the sport mode turns on slipping torque converter lockup starting at the 3-rd gear. It doubles the time before the torque converter repair in comparison with competing 6HP26 units.

The fluid change (Toyota WS) and filter replacement in A750 is performed with the help of partial and full replacement methods. The transmission electrics has delicate settings and sensitive to the oil level. Solenoids of this transmission can exhaust its resource prematurely and often get replaced, especially in gearboxes during first two years of series production. But in general, this transmission as well as majority of rear-drive Aisin automatic transmissions was produced to be "invincible".

Typical problems in A750E

The most common ordered repair kits for the first overhaul of the А750F unit, includes the following:

- Kit of gaskets and seals, Overhaul Kit

- Kit of all friction components

Overhauls of long-time neglected transmissions are notable for the fact that friction components should be replaced with all solenoids. The first package that gets burnt with cover plates: Forward С1 frictions. Then comes the turn of the В1 braking package.Other frequently burning frictions are located in Direct, C3 and 2nd brake packages.

Different problems with the torque converter, valve body and solenoids may occur as a result of long-time overheating or aggressive driving style on the off-road territory or on snow after 70 - 80 thousand kilometers.Transmission operation with worn-out torque converter clutch may lead to vibrations and fluid leakages through the pump seal. At the same time, the problem with the pump bushing occurs, and later you will have to deal with the pump failure. Valve bodies of А750, А761 and А960 have been constantly modified, improving their design, therefore selection of valve bodies and solenoids for replacement is performed specifically for each car according to its VIN-code. In general, the А750F unit is adjusted quite accurately for the torque converter and the valve body. Afterwards, you can drive for 150-200 thousand kilometers without serious problems for car owners, if ATF condition is controlled.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Toyota	4 RUNNER	03-08	5 SP R/4WD	V6 4.0L V8 4.7L
Toyota	MARK X	04-09	5 SP R/4WD	V6 2.5L
Toyota	SEQUOIA	05-08	5 SP R/4WD	V8 4.7L

How to repair this transmission (Videos)

A750E/F Valve Body Installation

750, 760, AB60 TRANSMISSION FILL

A750E/F Transmission Service

A750 A761 Introduction

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Manual A750E
pdf	www.at-manuals.com	Vacuum test valvebody A750E
pdf	www.at-manuals.com	Scheme A750E
web	www.at-manuals.com	Stall test A750E
web	www.at-manuals.com	Clutch application A750E
pdf	Sonnax	Valve Body Layout A750E
pdf	Sonnax	Vacuum test A750E/F
web	Sonnax	Diagnosing A750E/F 2-3 Flare After Overhaul
web	Sonnax	Toyota A750E-A761E Identification Guide
pdf	drive.google.com	A650E_A750EF_A761E manual

A4LD Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearbox Ford A4LD was designed for RWD vehicles (Explorer, Mazda pickup cars and many others) with engines from 2.5 up to 4 liters. This family of transmissions is manufactured in Bordeaux, France. After the update in 1995, this gearbox was provided with an electronic control, the letter "Е" was added to its name (A4LD-Е). In 1997, this gearbox became fully equipped with an electronic control unit and changed its name in accordance with a new classification- 4R44E,and after the update of several units, the 4R55E modification was released. Spare parts for repair of these gearboxes are interchangeable.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		9,5	4	Dexron VI

Technical issues and repair guidelines

The torque converter in these transmissions is the first component to be replaced during repair procedures. In most cases, transmission specialists order the Masterkit repair kit to fix this transmission. This kit includes all gaskets and seals, rings and friction components with discs, except filter and brake bands, which are ordered separately. Repair kits contain all necessary gaskets and spare parts of the valve body, other gearbox components and pan, to replace the old rubber, paper gaskets and plastic of the transmission, which served for more than 10 years.

This transmission is handed in for repair after failures of the brake band О.D.\Intermediate and the drum Overdrive. The drum Overdrive is also considered to be a soft spot and gets out of order together with the brake band and Servo piston of the brake band. When solving the abovementioned problems, specialists also replace the brake band piston INTM./ O.D.

Vibrations and overheating of this drum may lead to replacement of not only friction elements of the package Overdrive, steel discs, and bearing disc, but also of the pump support.In many cases, packages get burnt because of worn-out pump bushing and insufficient pump productivity. This problem can be detected by means of the leaking seal.

The repair of electrical components consists of replacement of EPC solenoids, solenoids shift (4), solenoids of the torque converter locking (TCC), which reached the end of their service life.The valve body often causes insufficient (on bushings) or excessive pressure. The valve body gets clogged with friction dust from the worn torque converter. If the torque converter friction is worn out to the glue layer, then it significantly speeds up the wear-out and clogging of solenoids and the valve body.The most replaceable clutch discs are friction elements of the Forward Clutch package and corresponding steel discs, which twofold outrun the package Direct in sales, other friction elements are replaced more rarely.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	AEROSTAR	95	4 SP R/4WD	V6 3.0L 4.0L
Ford	TRANSIT	0	4 SP RWD	L4 2.5L
Mazda	NAVAJO	91-94	4 SP RWD	V6 4.0L
Mazda	PICKUP	94	4 SP RWD	L4 2.3L V6 3.0L 4.0L
MCW	METROCAB	00-01	4 SP RWD	L4 2.5L

How to repair this transmission (Videos)

Teardown Inspection

5R44E 2-3 shift

5R55E Valve Body Shift Kit Installation

servo bore problems

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Remove and Install A4LDE
web	www.at-manuals.com	Scheme C-3
web	www.at-manuals.com	Clutch application
pdf	Sonnax	Valve Body Layout 4R/5R44E, 4R/5R55E
pdf	Sonnax	Vacuum test 4R44E-5R55E

A4AF3 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission A4AF-3, A4BF-3 was designed in 2000 by Hyundai specialists and was supposed to become a successor of the A4AF1 for FWD medium vehicles such as Hyundai Matrix, Elantra, Accent, with engine up to 2 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	190	6,3	4	SP-III

Technical issues and repair guidelines

This transmission is considered to be very reliable, enduring long-time operation with contaminated transmission fluid. After a proper overhaul with spare parts reassembly specialists can give 1-2 years warranty. Many spare parts for A4AF3, A4BF3 transmissions are interchangeable with the whole A4AF family of automatic transmissions.The list of common spare parts includes the following: closed filter with felt, which is replaced in the process of each reassembly of the transmission that covered 150- 180 thousand kilometers; the brake band, which is replaced with the whole set of friction components when smelling the burnt ATF (Brake bands for engines up to 1.8 liters and over 1.8 liters are different), the brake band is replaced with the seal when operating for a long time with worn-out spare parts of the torque converter; in many cases specialists order the kit of bushings for the overhaul.

Seal boots are unified and can be applied for all relative automatic transmissions from КМ175 to F4A33, they are ordered during each rebuilding. If seals are replaced, but the torque converter is left untouched, then after a short time the seal will start leaking again and, as a result, it will be required to reassemble the oil pump. Friction elements in the Direct Clutch\ Forward packs burn 3 times more frequently. In most cases, all friction components are ordered for complete overhaul.

Another problem of the A4AF1 became a real “headache” for specialists in the process of the A4BF3 transmission repair: the drum gets burnt in each 5-th automatic transmission which comes to repair services, because of worn bushings and consequent oil leakage.Typical design problem of the Overdrive unit lies in damage of bearings caused by side loads from the differential.

Specialists often have to repalce the whole set of 6 solenoids and wiring. Even if the problem occurs in only one solenoid, technicians have to replace all of them because of short resource of other solenoids.Sometimes the problem of one of the linear pressure solenoids may lead to harsh shifting or forced actuation of the 3-rd gear without error codes. Problems usually lie in the fact that the solenoid valve wears out the channel because of contaminated ATF, starts hovering and at some moment gets wedged. Cleaning only contributes to the problem and the repair does not cover expenses. Generally this transmission is reliable like Hyundai cars when avoiding unnecessary overloads and overheating.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	ATOZ	01-12	4 SP FWD	L4 1.1L
Hyundai	AVANTE	00-16	4 SP FWD	L4 1.6L
Hyundai	AVANTE XD	00-06	4 SP FWD	L4 1.5L 1.6L 1.8L
Hyundai	AVEGA	07-10	4 SP FWD	L4 1.5L
Hyundai	CLICK	02-10	4 SP FWD	L4 1.3L 1.4L 1.5L 1.6L
Hyundai	GETZ	04-08	4 SP FWD	L4 1.3L 1.4L 1.6L
Hyundai	LAVITA	01-07	4 SP FWD	L4 1.5L 1.6L
Hyundai	SONATA	01-05	4 SP FWD	L4 2.0L
Hyundai	VERNA	00-11	4 SP FWD	L4 1.3L 1.4L 1.5L 1.6L
KIA	AVELLA	00-02	4 SP FWD	L4 1.3L 1.5L
KIA	CLARUS	00-02	4 SP FWD	L4 1.5L
KIA	FORTE	03-16	4 SP FWD	L4 1.6L 1.8L
KIA	QIANLIMA	02-10	4 SP FWD	L4 1.4L
KIA	RIO	05-16	4 SP FWD	L4 1.4L 1.6L
KIA	SHUMA	00-01	4 SP FWD	L4 1.5L 1.8L
KIA	SPECTRA	00-04	4 SP FWD	L4 1.5L 1.8L
Zhonghua	FSV	13-15	4 SP FWD	L4 1.5L
Zhonghua	JUNJIE	12	4 SP FWD	L4 1.6L

How to repair this transmission (Videos)

A4AF3 With Code P0734

Instruction manuals and useful links

Link type	Source	Description
pdf	Atra	A4BF2/A4AF3 Problems Before and After Rebuild
pdf	automaticchoice.com	Scheme A4AF3

A4CF1 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed modern automatic transmission A4CF1 produced in 2005 and its more powerful modification A4CF2 from Hyundai were designed for cars with the engine capacity up to 2 liters. Since 2006, these automatic transmissions can be installed on all FWD small cars of Hyundai (Accent, Solaris, Ceed, Getz...) and Kia (Spectra, Forte, Cerato, Soul...).

The first modification A4CF1 had a lot of problems, therefore an updated modification named A4CF2 was released in 2005. Minor changes in electrical parts and computer settings were introduced in 2007 in order to prolong the transmission lifespan that may be comparable with the resource of the whole car.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	160	6	3	SP-III

Technical issues and repair guidelines

Typical problems during the first years of the transmission operation are related to change of ATF and filter replacement. It is recommended to replace all friction components together with the kit of gaskets and seals during the transmission rebuilding.

Common problems in A4CF2-\1:

The list of the most popular repair procedures for this transmission includes the valve body reassembly and replacement of solenoids. The most vulnerable failure-prone are VFS (EPC) solenoids and PWM solenoids. The problem is related to contaminated and hot (because of the torque converter) transmission fluid and resource wear-out. In many cases problems with electrical parts are caused by faulty wiring of solenoids.

Some problems may occur in the pump as a result of a long-time operation with the leaking seal, damaged bushing (applicable to A5HF1) and shaft vibrations.Specialists assume, that high temperatures and forced torque converter lock-up lead to rapid oil contamination and this suspended fluid clogs and wears out channels in the valve body and solenoids, leading to the oil pressure shortage in packages and early burning of friction components. A long-time operation with the pressure shortage and vibrating clutch lock-up leads to problems with the pump and some other unpredictable issues.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Hyundai	AVANTE HD/MD	06-12	4 SP FWD	L4 1.6L 2.0L
KIA	CEE'D	07-11	4 SP FWD	L4 1.6L 2.0L
KIA	CERATO	05-10	4 SP FWD	L4 1.6L 2.0L

How to repair this transmission (Videos)

A4CF1/A4CF2 valve body removal

A4CF2 Multiple solenoid codes

A4CF2 Shift Problems

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme A4CF1 A4CF2
pdf	www.at-manuals.com	Valve body valves A4CF1 A4CF2
web	www.at-manuals.com	Solenoid application chart A4CF1 A4CF2
web	www.at-manuals.com	Hydraulic pressure table A4CF1 A4CF2
web	www.at-manuals.com	Clutch application A4CF1 A4CF2
pdf	Sonnax	Valve Body Layout A4CF1

A340 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The range of 4-speed of automatic transmissions А340 (also known as AW30-40LE /-70LE according to Aisin classification) has been on the market since 1985 on RWD and 4WD Toyota Land Cruiser with the engine capacity from 2.5 up to 4 liters. The А340 unit is a middle class transmission which stands next to the range А40 of the class "mini".Toyota used the А340 series for all other powerful cars: Pickup, 4-Runner, Mark II, Hilux, Hiace, Previa, etc.There is a large number of modifications of А340 Series for engines with 2.5-3.2 liters capacity.The AW30-41 modification and 30-43 is still in demand as not expensive, low-maintenance, robust gearbox for "work horse" cars.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	300	11	4	Toyota T-IV

Technical issues and repair guidelines

Each modification in this transmission family had some updates in the electrical part (linear solenoids) of the valve body and torque converter.This transmission is quite simple, balanced and has a huge resource reserve. The repair of this gearbox usually takes place in cars with high mileage and includes replacement of worn-out spare parts. It is almost always the case that the torque converter of this transmission is handed in for repair. Operating with the worn-out lockup leads to the output shaft beating and excessive side load on the pump, seal, and bushing.

Operation of the A340-equipped car with contaminated fluid results in wear-out of bushings through which the oil leaks out leading to main pressure losses. Almost all bushings are replaced together with rings and gaskets included in the repair kit. Firstly, the pump bushing gets out of service. Because of damaged bushings the pump may have performance efficiency problems leading to the oil pressure shortage in packages, therefore friction components of packages primarily involved in operation start slipping and get burnt.Commonly, frictions (with steel discs) of Forward package get burnt. The brake band is standard for all modifications. It is replaced when the car comes to repair with burnt fluid. The replacement of solenoids is common for old cars (produced before 1998).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
KIA	PREGIO	00-03	4 SP RWD	L4 3.0L

How to repair this transmission (Videos)

A340E Teardown

340E Mistake

AW4 TRANSMISSION TEARDOWN

A340 Valvebody Installation Instructions

Basic Hydraulic Operation

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme A340
web	www.at-manuals.com	Solenoid identification A340
web	www.at-manuals.com	Solenoid/component application chart A340
web	www.at-manuals.com	Clutch application A340
pdf	Sonnax	Valve Body Layout A340E, A340F
pdf	drive.google.com	A340E Service information
web	Sonnax	Toyota A340E/F Identification Guide

8HP45 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The automatic transmission ZF8HP45 with the longitudinal arrangement was manufactured as an updated version of automatic transmissions ZF6HP21, ZF6HP32.

The pilot prototype was designed in 2008 and after a short run-in on the BMW of 7-th series, ZF8HP became widely used on vehicles with a maximum torque of 450 Nm for gasoline engines (ZF8HP45) and 700 Nm for ZF8HP70 for BMW diesel engines. According to the abovementioned data, the numbers 45 and 70 in the name of the automatic transmission mean the index of maximum torque sent by the transmission.

In subsequent years ZF increased its range of automatic transmissions related to this family from ZF8HP23 for the class "mini" with 1.6 engines to ZF8HP90 for cars with engine capacity equal to 6-liters. Achievements of these automatic transmissions exceeded all expectations and resulted in a lot of praising responses, and childhood illnesses were extremely quickly corrected, unnoticed for the repair of automatic transmissions.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
8	AT	RWD/AWD	500	9	6	BMW 222305397

Technical issues and repair guidelines

For the present these unique transmissions appear in services with the purpose of the oil and filter change.The oil change should be performed in special services where it is also recommended to check the oil level and transparency of the old oil. This transmission is very sensitive to the oil quality, because more than a half of components in this transmission is made of aluminum.The torque converter repair is included in the list of mandatory procedures during ZF8HP transmissions reassembly after travelling 200-300 thousand kilometers.In case of aggressive driving behavior it is advisable to test the torque converter concerning wear-out of the clutch locks and signs of vibrations after 100 thousand kilometers. The oil should be regularly tested for transparency and presence of inclusions.

The first overhaul of 8HP transmissions with burned oil require not only repair of the torque converter but also change of all friction clutches.The most popular spare parts for 6НР transmission as well as for its predecessor are the valve body separator plate made of metal with rubber-covered tracks.Another issue is related to Mechatronics with solenoids which get burned in the summer time traffic jams because of overheating oil of worn-out torque converter lock-up and metal dust falling on magnetic detectors.One of the soft spots turns out to be the aluminum of E clutch – damage of splines: Wheel-hub, HUB "E" Clutch".The repair process also may include the Planetary gear P3 replacement (by 3 satellites for 8HP45 transmission).

It is suggested that the main issue of ZF transmissions related to the solenoid-electro-regulators VFS strong dependency on the oil flow velocity, oil contamination and dust settling inside solenoids that lead to solenoids malfunction resulting in wrong pressure parameters which differ from figures expected by the computer. Conflicts with the computer adjusting to the abovementioned circumstances lead to various unpredictable problems like clutches slippery, pushes and kicks.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Alfa-Romeo	169	16	8 SP R/4WD	L4 2.0L 2.2L
Alfa-Romeo	GIULIA	15-16	8 SP R/4WD	L4 1.4L 2.0L 2.2L V6 3.0L
Audi	Q7	10-11	8 SP R/4WD	V6 3.6L
BMW	1-SERIES	11-16	8 SP R/4WD	L4 1.6L 2.0L L6 3.0L
BMW	2-SERIES	13-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	3-SERIES	11-16	8 SP R/4WD	L4 1.6L 2.0L L6 3.0L
BMW	3-SERIES GT	13-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	4-SERIES	13-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	4-SERIES GRAN COUPE	14-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	5-SERIES	10-16	8 SP R/4WD	L4 1.6L 2.0L L6 2.5L 3.0L
BMW	5-SERIES GT	09-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	6-SERIES GRAN COUPE	12-16	8 SP RWD	L6 3.0L
BMW	7-SERIES	10-15	8 SP R/4WD	L6 3.0L
BMW	X1	11-16	8 SP R/4WD	L4 1.6L 2.0L L6 3.0L
BMW	X3	10-16	8 SP R/4WD	L4 1.6L 2.0L L6 3.0L
BMW	X4	14-16	8 SP 4WD	L4 2.0L
BMW	X5	13-16	8 SP R/4WD	L4 2.0L L6 3.0L
BMW	X6	10-14	8 SP 4WD	L6 3.0L
BMW	Z4	11-16	8 SP RWD	L4 2.0L
Chrysler	300	11-16	8 SP R/4WD	V6 3.0L 3.6L
Dodge	CHALLENGER	14-16	8 SP RWD	V6 3.6L V8 5.7L 6.4L
Dodge	CHARGER	12-16	8 SP R/4WD	V6 3.6L
Dodge	DURANGO	12-16	8 SP R/4WD	V6 3.6L
Dodge	PICKUP/RAM 1500	12-16	8 SP R/4WD	V6 3.6L
Jaguar	F-TYPE	15-16	8 SP RWD	L4 2.0L
Jaguar	XE	15-16	8 SP R/4WD	L4 2.0L V6 3.0L V8 5.0L
Jaguar	XF	15-16	8 SP RWD	L4 2.0L
JEEP	GRAND CHEROKEE	11-16	8 SP R/4WD	V6 3.0L 3.6L
JEEP	WRANGLER UNLIMITED	15-16	8 SP 4WD	V6 3.6L
Lancia	THESIS	11	8 SP R/4WD	L4 1.8L L5 2.5L V6 3.6L
Land-Rover	DISCOVERY(LR3)	10-11	8 SP R/4WD	L6 3.7L
Volkswagen	AMAROK	12-16	8 SP R/4WD	L4 2.0L V6 3.6L

How to repair this transmission (Videos)

Components and operation

Valve Body

ZF8HP70 Main Case

ZF8HP70 Pump Removal

ATSG Transmission Tip

Ray's Garage- ZF8HP70 Unit Disassembly

Ray's Garage Tech Tip: ZF8HP55

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout ZF8HP45, ZF8HP70
pdf	Sonnax	Valve Body Layout ZF8HP55
pdf	Sonnax	Vacuum test ZF8HP45, ZF8HP70

722.9 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 7-speed automatic transmission Mercedes 722.9 was produced in 2004 (G-tronic) and considered to be a masterpiece from Mercedes Benz for С-class models. It was used for all RWD Mercedes cars from С180 to С350. This transmission was designed on constructive basis of the 6-th series of automatic transmissions and many spare parts are interchangeable.

W7X550 - for engines up to 3,5L and 550Nm; ATF capacity - 8,6L;
W7A700 - for engines up to 5,5L and 700Nm; ATF capacity - 8,9L;
W7B700 - for engines up to 6,3L and 850Nm; ATF capacity - 9,1L.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
7	AT	RWD/AWD	550-850	9,1	5	236.15

Technical issues and repair guidelines

For this transmission, Mercedes engineers used the controlled slipping of the of the torque converter frictions, which starts from the first gear. In many cases, this peculiarity leads to rapid fluid contamination by the torque converter frictions and premature necessity for fluid change and the torque converter rebuilding.

The whole family of 722.9 transmissions is sensitive to issues with fluid shortages and its contamination. The main spare parts in this transmission are wearable teflon rings, which are crucial for accurate gear shifting. There are two types of friction components for this gearbox- one-sided and two-sided.In most cases, frictions of the K2 package get replaced. The K1 frictions are replaced less often as well as K3 frictions, but repair specialists order a full kit of friction discs in case of burnt oil.

The first typical problem of the 9th series is related to the failure of the connector electronic board - the sensor Y3 / 8n1 gets burnt. In most cases, this board is replaced. The resource of solenoids heavily depends on the oil contamination level and leakproofness of packages.The second common problem of this transmission is the damage of the housing bell caused by vibrations from aggressive driving.

The valve body in this transmission operates at temperatures up to 130º and it is very sensitive to overheated and contaminated fluid and shavings. Small springs of the valve body can break down, solenoids may get clogged. Experts assume that abnormal operation of the valve body leads to shortages of oil pressure in the 722.9 unit, frictions get burnt and other problems occur in the chain order. Since Mercedes engineers provided the valve body repair without the transmission removal, thus it is possible to detect the abovementioned problem and solve it by means of reassembly and cleaning.

Problems also occur in the multi-function switch (Servo mechanism module). Although components of this transmission are quite reliable, but problems in the electrical part have a negative impact on the oil pump and consequently result in issues with the rear planetary gear and bushings.The torque converter repair is one more operation which should become a preventive measure to prolong the service life of this transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	CLC	08-11	7 SP RWD	V6 2.5L 3.5L
Mercedes-Benz	CLK	04-09	7 SP RWD	V6 2.5L 3.0L 3.5L V8 5.0L 5.5L 6.3L

How to repair this transmission (Videos)

722.9 Teardown Inspection

722.9 Valvebody Overhaul

(TCM) repair part 1

(TCM) repair part 2

Transmission, pump damage

722.9 TCC adaption

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Diagnosis, Repair Advanced Training 722.9
web	www.at-manuals.com	Electrohydraulic control module 722.9
web	www.at-manuals.com	Solenoid and electronic control identification 722.9
web	www.at-manuals.com	CheckBalls 722.9
web	www.at-manuals.com	Solenoids work 722.9
web	www.at-manuals.com	Scheme 722.9
pdf	Sonnax	Valve Body Layout 722.9
web	mercedesmedic.com	722.9 7G Tronic Automatic Transmission Problems and Solutions

722.6 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed Mercedes automatic transmission 722.6 was to supposed to be an ideal transmission for flawless cars. It was installed on Mercedes, Porsche 911, Jaguars, Jeeps and many other RWD models with the engine capacity from 3 to 6 liters.This unique transmission was duly appreciated on the market, and was selected for many exclusive cars. For many years, this unit was by American (Chrysler, Jeep, Dodge), and European(Porsche, Jaguar, ...) automakers.

W5A330 - up to 3,5L engines 350Nm, full capacity 8,7L ATF;
W5J400 - up to 4,3L engines 420Nm, full capacity 9,1L ATF;
W5A580 - up to 6,0L engines 580Nm, full capacity 9,3L ATF.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD	350, 420, 580	9,5	4	236.14

Technical issues and repair guidelines

Many experts assume that this transmission has its design peculiarities which require some skills from repair specialists. This transmission is maintenance-friendly, it has a huge resource for transmission components and can serve for a long time, when following the rules of operation and visit a repair shop for well-timed overhaul and replacement of repair parts.

In many cases, repair specialists have to fix the torque converter and replace rubber and plastic spare parts. In most cases, technicians have to replace all friction elements, even if they haven't exhausted their resource.

The electric board with speed sensors get out of order because of regular overheating and contaminated ATF. Operating with the faulty valve body and electrics leads to general oil starvation, wear-out of bushings, vibrations and wear of other units of 722.6 series. Separators of rear and front overrunning clutches are frequently replaced in the process of repair services.If the transmission is used with a worn-out torque converter for a long time, then vibrations and metal debris damage not only bushings, but also friction surfaces of the pump cover. In this case, masters replace the pump cover with gears. Frequently, it is required to replace a rear bushing of the K2 drum, which is damaged by vibrations from unevenly wornout frictions.

The repair of the 722.6 torque converter is one of the most demanded and highly-priced procedures because of the transmission complex design and record number of spare parts. The operation of the 6th series automatic transmissions with the faulty torque converter has a negative impact on the valve body. Therefore, it is recommended not only to completely change ATF, but also hand in the torque converter for replacement of the friction coupling.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	VANEO	01-05	5 SP FWD	L4 1.7L 1.9L

How to repair this transmission (Videos)

Teardown Inspection

Teardown inspection Part 2

Bellhousing Swap & Reassembly

Valvebody overhaul

B2-B3 Clutch Drum Assembly

4Matic Quick Tip

NAG1 5-Speed Transmission Power Flow

Plate Diagnose

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme
web	www.at-manuals.com	Valve Body 722.6
web	www.at-manuals.com	Solenoids 722.6 transmission
web	www.at-manuals.com	Identify type of 722.6 transmission p1
web	www.at-manuals.com	Identify type of 722.6 transmission p2
pdf	Sonnax	Valve Body Layout 722.6
pdf	Sonnax	Vacuum test 722.6/CHRYSLER NAG 1

722.5 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 722.5 had been used on rear- and four-wheel drive vehicles (Gelendwagen) from 1990 to 1997. The 722.5 design is based on successful 4-speed solution 722.3. The construction of the 3-rd series is complemented with advanced electronic control and the clutch package Overdrive. Almost all componentsin the 722.5 unit are interchangeable with 722.3. All typical problems are also identical.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD	580	8,5	4	236.14

Technical issues and repair guidelines

The repair kit of gaskets and seals is ordered for reassembly of 722.5. In addition to typical overhaul procedures for this transmissions (replacement of gaskets and seals), repair specialists also replace the oil filter. The overhaul certainly includes repair of the torque converter caused by wear-out of friction linings of actively operating lock-up clutch (leaking pump seal is the sign of wear-out). In many cases, the repair consists of replacement of current pump seal and the pump bushing.

Transmission specialists also frequently have to replace all friction components. The package Reverse (piston) is replaced quite often because of damaged springs (because of old age) which are harmful for the whole unit.

The electrical part in the 722.5 unit (as well as hard parts) is quite reliable and its service life is compatible to the car's lifespan. Automatic transmission of 5-th series endures harsh operation conditions without any serious problems in contrast to following generations of 5- and 7-speed automatic transmissions 722.6 and 722.9.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	300SL	90-93	5 SP RWD	L6 3.0L
Mercedes-Benz	S CLASS	94-95	5 SP RWD	L6 3.2L

How to repair this transmission (Videos)

722.5 Mercedes Transmission

722.5 Valvebody Overhaul

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme

722.3 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The family of 4-speed automatic transmissions Mercedes 722.3 - 722.4 has been used since 1981 on all popular RWD Mercedes models with engine capacities from 2.3 up to 5 liters, which operate for decades.

The difference between series 722.3 (W4A40) and 722.4 (W4A20) is externally indeterminate, because both gearboxes operate flawlessly. Before 1997 almost all components for 722.3 and 722.4 had been interchangeable, apart from difference in gaskets and frictions. The 5-th series is practically identical to the 722.3.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	570	8,6	4	236.12

Technical issues and repair guidelines

A typical kit for the 722.3 transmission reassembly includes Overhaul kit (repair kit of gaskets and seals), which differs for 722.3, 4-th and 5-th series. The torque converter usually gets in repair services in the process of transmission reassembly.

Old transmissions often have problems with the Reverse package , where springs get damaged causing problems for following components:

- Damper cone ring (B-3 / Reverse Clutch) for 722.4.

- Spring with the holder ОЕМ№...993-2702,

- Piston

The most frequently bought part for repair is the brake band.It is also required to replace the pump cup in all vehicles which went through oil starvation or the torque converter hub overheating (caused by usage of the worn-out torque converter). The electrical part of this transmission is so simple and reliable that in rare cases repair specialists have to replace kick-down solenoid.The only problem of the valve body is the dirt, which clogs channels. With time transmission specialists have to replace plunger springs. Valve bodies are mainly repaired and cleaned, spare parts usually don’t get replaced.

All problems of these reliable transmission are related to ATF shortages, contaminated ATF, overheated ATF because of clogged radiator and defective torque converter. If the ATF change is well-timed and the radiator stays more or less clean in-and-out, then these transmissions can operate without the overhaul over 300 thousand kilometers. The only required preventive repair is replacement of the torque converter spare parts. If the vehicle equipped with this transmission travels over 200 thousand kilometers, then it’s a high time to perform the abovementioned torque converter repair procedure.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercedes-Benz	400	92-93	4 SP RWD	V8 4.2L
Mercedes-Benz	500	90-93	4 SP RWD	V8 5.0L
Mercedes-Benz	S CLASS	94-95	4 SP RWD	L6 3.4L V8 4.2L 5.0L

How to repair this transmission (Videos)

722.424 Transmission Rebuild

722.424 Teardown

722 4 Pressure Control cable connection

722 424 Valve Body Rebuild

722.3 Valve Body Rebuild

722.3 K2 Drum Overhaul

B1 Piston Cap Tool

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme
pdf	www.at-manuals.com	TransTec Manual
web	www.at-manuals.com	Application chart
pdf	jenniskens	Transmission Adjustment Guide

6DCT450 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The main constructive idea for shifting gears in DCT WD is adopted from n-speed transmissions and the shifting is performed by means of hydraulics and solenoids controlled by the control unit. Therefore many age-related problems are the same as n-speed transmissions: metal friction suspended material from hot ATF clogs valves of the valve body and solenoids, gets on the rubbing surfaces and promotes the wear of aluminum by vibrations and sticking of valves, especially when the friction clutches are worn out, that leads to a chain reaction of metal wear and further contamination of oil.

Therefore the 6DCT450 has more capacious outside filter in comparison with other CVTs. There are several filters-cartridges modifications, which are different for DCT450 and DCT470. The filter is included in the overhaul repair kit, but Gertrag engineers recommend to replace this filter more often, especially if the transmission has been used for a long time.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	DCT	FWD	450	1,8	1,8	75w90

Technical issues and repair guidelines

For the DCT450 transmission reassembly, specialists order the repair kit of gaskets and seals. Repair kits contain gaskets (required as a minimum), which affect the operation of this delicately adjusted transmission. The wearout of Teflon rings also has a major impact on the transmission operation. Replacement of the filter with ATF is a typical repair procedure recommended for maintenance of WD Powershift transmissions. It is advisable to change oil more often and not later than after 45-50 thousand kilometers.

For the overhaul of 6DCT450 it is common to replace solenoids in order to solve problems with the valve body. The overhaul of the clutch basket in 6DCT450 is accompanied by order of springs and retainers-clips. When the dry clutch gets out of order specialists have to replace the step motor or more frequently the transmission itself

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	C-COUPE	11	6 SP FWD	L4 2.0L
Ford	C-MAX	11-16	6 SP FWD	L4 2.0L
Ford	ESCAPE	12-16	6 SP 4WD	L4 2.0L
Ford	FOCUS	06-16	6 SP FWD	L4 1.5L 2.0L
Ford	GALAXY	10-15	6 SP FWD	L4 2.0L 2.2L
Ford	MONDEO	08-15	6 SP FWD	L4 1.6L 1.8L 2.0L 2.2L
Ford	S-MAX	10-15	6 SP FWD	L4 2.0L

How to repair this transmission (Videos)

Learning The Getrag's DCT450

Hard Parts Identification Video

Disassemble clutch

Disassembly and measurement of clutch components

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 6DCT450
pdf	www.getrag.com	Specifications 6DCT451
pdf	drive.google.com	Repair manual 6DCT450

62TE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 62TE is a 6-speed automatic transmission produced in 2006 as the part of АТ family Chrysler "UltraDrive". The FWD 4-speed A604 (41TE) is taken as a base model for 62TE in terms of design. The 62TE is produced for FWD cars Chrysler with the engine up to 4-liters (sedans Sebring, crossovers Pacifica, and minivans Town & Country, Voyager and Caravan from Dodge).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD		8,5	5,2	Mopar ATF+4

Technical issues and repair guidelines

Repair procedures and typical problems

Repair kits for the 62TE transmission include the following:

- Repair kit of gaskets and seals

-Kit of friction components

-Kit of steel discs

A standard set for reassembly of the automatic transmission with burnt friction elements includes the kit of pistons (6 pieces).The block of solenoids, separately installed solenoid EPC and sensor EPC serve as a typical spare part for these transmissions when the car runs 200 thousand kilometers.

EPS solenoids and solenoid of the torque converter clutch lock-up are the first to wear out in the valve body. Solenoids are replaced together with worn-out rings and gaskets in order to avoid early overloading of these delicately adjusted electric regulators.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chrysler	200	06-14	6 SP FWD	V6 2.7L 3.5L 3.6L
Chrysler	200	10-14	6 SP FWD	L4 2.4L
Chrysler	PACIFICA	07-08	6 SP F/4WD	V6 4.0L
Chrysler	SEBRING/SEBRING CONVERTIBLE	06-12	6 SP FWD	L4 2.4L V6 2.7L 3.5L
Chrysler	TOWN & COUNTRY	07-16	6 SP FWD	L4 2.8L V6 3.6L 3.8L 4.0L
Chrysler	VOYAGER	07-08	6 SP FWD	L4 2.8L
Dodge	AVENGER	07-14	6 SP FWD	V6 2.7L 3.5L 3.6L
Dodge	AVENGER	10-14	6 SP FWD	L4 2.4L
Dodge	CARAVAN	07-16	6 SP FWD	L4 2.8L V6 3.3L 3.6L 3.8L 4.0L
Dodge	CARGO VAN	11-15	6 SP FWD	V6 3.6L
Dodge	JOURNEY	08-16	6 SP F/4WD	L4 2.4L V6 2.7L 3.5L 3.6L
Dodge	PROMASTER	13-16	6 SP FWD	V6 3.6L
Fiat	FREEMONT	11-16	6 SP F/4WD	L4 2.0L 2.4L V6 3.6L
Lancia	MPV	11-12	6 SP FWD	L4 2.8L V6 3.6L
Volkswagen	ROUTAN	08-13	6 SP F/4WD	V6 3.6L 3.8L 4.0L

How to repair this transmission (Videos)

62TE Final assembly

62TE Teardown

2TE Valvebody Overhaul

62TE Updates

Solenoid Pack Pin ID

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme 62TE
pdf	www.at-manuals.com	Catalog 62TE

5R55N Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 5R55N (5R55W, 5R55S) was released in 2000 and found application in Ford Explorer and THUNDERBIRD. Besides Ford and Lincoln, it was installed on Mazda pickup trucks in Asia and on Jaguar S-type (for 2 years). In 2002, the problematic 5R55N was replaced by a new sub-modification 5R55W, and in 2003 the 5R55S was released with some updates. This transmission is installed on RWD and 4WD vehicles with quite powerful engines (from 3 up to 5 liters). In terms of design, this transmission belongs to the 4R44 - 4R55E family .

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD		11,5	5	MerconV

Technical issues and repair guidelines

The design of this transmission includes a forced electronic control of the torque converter lock-up. It complicates the system operation and makes it dependable on the ATF quality. The torque converter of the automatic transmission clogs the valve body quite rapidly and turns out to be the main reason of the valve body contamination and failure of the solenoids.

During the first years of operation, it is required to monitor possible leakages (quantity and quality of oil MerconV - 11.5 liters) and the filter condition. The 5R55N is very sensitive to contaminated ATF and the torque converter repair is the first in the list of rebuilding procedures.

The most common repair procedure is replacement of the filter and the pan gasket. There are 3 modifications of filters depending on the pan dimensions and year of manufacture.In addition to spare parts, it is frequently required to replace brake bands (Intermediate - O.Drive). One more constructive problem is the failure of the band locking plate caused by sidesway and vibrations. They are replaced together with the servo piston.In many cases, sensors of the output\input shaft speed (VSS\ISS) also get replaced.

In most cases, friction components of the Forward package get burnt, but specialists replace not only a full kit of friction discs, but also steel discs and the bearing disc of this package.The pump valve is the most vulnerable element in the pump. Sticking of the valve leads to delays in gear shifting or even to the lack of the pull-rod at growing engine revs.

The valve body is repaired quite often, therefore Sonnax released many repair kits for rebuilding of these transmissions. This problem is common for all valve bodies produced in the early 2000s, in which the torque converter locking was performed too early and accompanied by strong slippage. It is complicated by the fact that drivers in these situations too often use aggressive accelerations and too rarely changed ATF and the torque converter friction elements.

It is recommended to install additional cooling radiator on “old” cars, which went through the ATF overheating and burning of friction elements.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	THUNDERBIRD	2	5 SP RWD	V8 3.9L
Jaguar	S TYPE	00-02	5 SP RWD	V8 4.0L
Lincoln	LS	00-02	5 SP RWD	V6 3.0L V8 3.9L

How to repair this transmission (Videos)

5R55S - Repair - Part - 1

5R55S - Repair - Part - 2

5R55N Valvebody Quick tip & Repair

5R55S Valve Body

Teardown with code P0775

5R55S Servo Bore Repair

5R55W Servo Bore Repair

5R55W TEAR DOWN

5R55W SERVO BUSHING INSTALL

5R55W SUBASSEMBLY

Instruction manuals and useful links

Link type	Source	Description
pdf	www.valvebodypros.com	Initial Engagements
pdf	www.at-manuals.com	Repair manual 5R55W, 5R55S
pdf	Sonnax	Valve Body Layout 5R55N
pdf	Sonnax	Valve Body Layout 5R55S, 5R55W
web	Sonnax	Check Balls 5R55W/S

5R55E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5R55E is an automatic gearbox produced by Ford. It is the five-speed automatic transmission, which was widely applied in both two and all-wheel drive cars. This transmission found application in various Ford models (such as Lincoln and Mercury).

Regarding the mechanical part, the 5R55E is similar to the 4-speed 4R55E. The 5R55E has the adaptive shift control and directional high energy frictions. It was the 1-st five-speed electronically-controlled gearbox in an American car.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD		9	3	Dexron VI

Common issues:

1)Malfunction of solenoids – this transmission employs solenoids to control many of its functions, including the gear shifting process and operation of the torque converter lock-up. The simplest and method of testing solenoids is to use the ohm meter, which measures solenoids resistance.

2)High chance of overheating: like any other automatic gearbox, the 5R55E is subject to overheating, especially if it is exposed to severe operation conditions. Overheating frequently leads to the transmission failure, therefore transmission repair specialists often recommend installing transmission coolers, which help to cool down the transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	AEROSTAR	97	5 SP R/4WD	V6 4.0L
Ford	EXPLORER/SPORT TRAC	97-08	5 SP R/4WD	V6 4.0L
Ford	RANGER	97-11	5 SP R/4WD	L4 2.3L V6 3.0L 4.0L
Mazda	PICKUP B SERIES	97-10	5 SP R/4WD	V6 4.0L
Mercury	MOUNTAINEER	98-00	4 SP R/4WD	V6 4.0L

How to repair this transmission (Videos)

5R55E Teardown

5R55E transmission P0733 3rd. Incorrect gear ratio

5R55E Valve Body Shift Kit Installation

INSTALLATION PROBLEM PART 1 OF 3

INSTALLATION PROBLEM PART 2 OF 3

INSTALLATION PROBLEM PART 3 OF 3

Instruction manuals and useful links

Link type	Source	Description
pdf	Atra	2-3 Flare in the 5R55E
pdf	drive.google.com	Repair manual 5R55E

5R110W Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 5R110W was released in 2003. This transmission was mainly intended for all-wheel drive pick-ups and powerful off-road vehicles produced by Ford. This transmission turned out to be quite popular. It had been produced for 10 years before being replaced by the fully automatic 6 speed transmission. The strengthened design is one of the main peculiarities of this transmission. The arrangement of drive shafts, which are positioned close to each other, allowed engineers to reduce the dimensions of 5R110W without any harm to its reliability. This gearbox is used in cars with the engine capacity up to 6 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	AWD	1100	17,7		Mercon SP

The extensive application of automatic systems positively affected user-friendliness of this transmission, but at the same time, this step had a negative impact on reliability of 5R110W.

Control units, sensors and cables of this transmission are extremely sensitive to frequent changes of temperature, and they get out of order quite early. The complexity of repair of this transmission lies in issues with diagnostics. Even with the use of special equipment, it may be quite problematic to determine the source of the problem on the first try. It complicates the repair process, and increases the cost of its implementation.

The repair and service maintenance of the 5R110W transmission is notable for its complexity and must be performed by professionals. Even ATF change cannot be performed without special equipment. Problems with the valve body are typical for this transmission. When the mileage reaches 200-250 thousand kilometers solenoids fail to function and should be replaced. In addition, transmission repair specialists often have to perform a complex procedure of cleaning oil supply channels in the valve body.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	E-SERIES	97-16	5 SP RWD	V10 6.8L V8 5.4L 6.0L
Ford	EXCURSION	03-05	5 SP R/4WD	V8 5.4L 6.0L DIESEL V10 6.8L
Ford	F-250 SUPERDUTY /F-350 SUPERDUTY	03-10	5 SP R/4WD	V8 5.4L 6.0L DIESEL 6.4L V10 6.8L
Ford	F-450/550 SUPER DUTY	03-08	5 SP R/4WD	V8 6.0L DIESEL

How to repair this transmission (Videos)

(TorqShift)Transmission Teardown Inspection

(TorqueShift) Transmission Part 2

Transmission Teardown Ford 5R110W

Vacuum Testing - 5R110W

18:03 5 вещей которые НИКОГДА нельзя делать на АКПП (автоматической коробке передач). JoRick Revazov Рекомендуемые вам 1:02:16 5R110 rebuild (reassembly ) western truck and tractor repair 3,9 тыс. просмотра 36:10 5R110W Teardown Gary Ferraro 1,2 ты

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme 5R110W
web	Sonnax	6 Key Features to Understand in Ford E4OD, 4R100 & 5R110W TC

5L40E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission 5L40E was designed in 1999 jointly with the 4-speed 4L40E. It became widely used on RWD vehicles of GM and BMW with engines from 2.0 up to 3.6 liters (340 Nm) since 2000. This transmission was especially preferred by BMW (from BMW 3 (4L40E) to BMW 5 and Х5 (5L40E). Then these transmissions were commonly used across the globe: the USA (BMW, Opel, ...), China and Australia (Saturn, Cadillac etc.) and for Land Rover and Cadillac in the UK. The 5L40E transmission is designed on structural basis of 4L60E tested on American roads and produced on GM plant in Strasbourg, France.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD	420	9	6	Texaco ETL-7045 E / Dexron VI

Technical issues and repair guidelines

One of typical problems for the 5L40E during the first years of production is the radiator temperature regulator failure resulting in problems with the torque converter. The torque converter is handed in for repair during the reassembly. Experts assume that the torque converter cannot endure frequent forced switch-on of the clutch lock-up, its friction lining burns faster than other friction elements leading to dirt accumulation in the pump, valve body and solenoids and consequently all other transmission units.

Friction elements of the pack (Direct) (one-sided with internal and external teeth) burn twice as often as the Forward pack. Cover plates of the Direct pack are commonly replaced together with clutches. O.Dr.; Reverse frictions also get burnt quite often.The tight fit of rubber covered pistons is an unpleasant peculiarity of 5L40E repair, caused by features of the rotor type oil pump with its huge pressure potential.The kit of rubber-covered pistons is usually ordered for the overhaul.

PMW solenoids rapidly wear out instead of the valve body channels and plungers.Problems with solenoids which exhausted their resource and dirty valve body lead to insufficient pressure in the line that may result in ATF overheating because of slipping frictions, vibrations caused by uneven wear-out and cranking by bushes.

The kit of bushings is a typical order for repair of the 5L40E, which went through a long-time oil starvation at high speeds. One of the most common problems is the pump stator channel wear-out leading to the oil pressure decrease. The pump stator valve is also replaced quite often.

The valve body primarily suffers because of modes settings, when PWM-solenoids open the channel for ATF not immediately on full cross-section, but step-by-step opening and closing it. Movement acceleration of a hot pulp occurs in the narrowest area because of ATF and dirt. The torque converter transmits dirt to the transmission by means of worn-out clutch of the valve lock-up. Solenoids and the oil pump reach the end of their service life earlier than the valve body. It is a trigger for car owners to change oil and solenoids avoiding the valve body wear-out.

The 5L40E is considered to be a robust and reliable transmission, when preserving it from heavy oil contamination with friction dust, which wears transmission components.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Cadillac	SRX	03-10	5 SP R/4WD	V6 3.6L V8 4.6L
Cadillac	STS	04-09	5 SP R/4WD	V6 2.8L 3.6L V8 4.6L

How to repair this transmission (Videos)

Pump Overhaul

Initial Findings

Shift Solenoid Reconditioning

Torque Converter Inspection

Cone set

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 5L40
web	www.at-manuals.com	Check Balls 5L40e
web	www.at-manuals.com	Solenoid application chart 5L40e
pdf	Sonnax	Valve Body Layout 5L40-E
web	Sonnax	5L40E/5L50-E Loss of Reverse or TCC

5HP24 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission ZF 5HP24 was designed for powerful 6 and 8-cylinder engines (diesel and 2.4 - 4.5 liter IC-engines) in AWD and RWD high-priced Audi and BMW models (5-th and 7-th series Х5...). It is an intermediate transmission unit between famous 5HP19 and powerful 5HP30. It had been used since 1995 up to 2005.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD/FWD	440	9,7	4-5	LT -71141

Technical issues and repair guidelines

If this transmission is handed in for repair, transmission specialists have to change ATF, replace not only filter and numerous spare parts, but also the input drum of the clutch package А, which has problems with a circlip. In most cases, the input drum of the clutch package А is rebuilt rather than replaced with a new one. The whole kit of frictions is replaced in case of burnt oil.

In terms of design, the whole package А is considered to be a weak spot. The number of friction components and their diameters were increased several times in the process of manufacture, but still this package is the first to get burnt when transmitted torque reaches the maximum.

The second typical problem of this transmission (in addition to the drum А replacement) is the hub bearing (В). Vibrations caused by overloads damage the bearing and then the hub. One of the main causes for this problem is related to fluid shortages. Almost each overhaul (if the overhaul kit is not ordered) involves replacement of seals. Another typical problem for “old” 5HP24 is the one-way clutch F.

Old and overheated cars (older than 10 years) often require replacement of wiring in solenoids.Solenoids are the main spare parts among electrical components of this transmission. The torque converter is a separate issue of automatic transmission.The torque converter is considered to be the soft spot for transmissions of powerful vehicles, but in case with this transmission this problem is especially vivid. The 5HP24 unit is the second transmission among the most frequently repaired ZF transmissions. This transmission is also included in the world top 5 transmissions for overhaul coming after 5L40 and Audi 01P/N/M family.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
BMW	5-SERIES	96-04	5 SP RWD	L4 2.0L L6 2.2L 2.5L
BMW	7-SERIES	01-02	5 SP RWD	L6 3.0L
Jaguar	VANDEN PLAS	98-02	5 SP RWD	V8 4.0L
Jaguar	XJ8	98-03	5 SP RWD	V8 3.2L 4.0L
Jaguar	XK8	97-02	5 SP RWD	V8 4.0L

How to repair this transmission (Videos)

ZF5HP24 Teardown

ZF5HP24 Transmission common problems

Assembly Tip, A clutch Drum

Valvebody Quick Tip

Valvebody Assembly

No Reverse Hot

Broken Input Clutch Drum

Instruction manuals and useful links

Link type	Source	Description
pdf	Valve Body Pro	T-Case Problem RangeRover 5HP24
web	www.at-manuals.com	Application chart 5HP24
pdf	www.at-manuals.com	Spare parts catalog 5HP24

4T65E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed 4T65E was designed on the basis of the 4T60 transmission. In 1991, this gearbox was modified for FWD vehicles with engines (2-4 lit.). After testing, this transmission has been supplied to the market since 1993. The 4T60E was modified in 1993 and renamed as 4T65E. This gearbox is a robust product of GM, which properly operates for the first 5-7 years of service. The 440-T4 has been operating since 1983 on Cadillac named as 4T60, and considered to be quite convenient and repairable. Heavy duty (HD) modification is able to work in couple with 440 Nm engines.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD/AWD	380	12,7	7	Dexron VI

Technical issues and repair guidelines

The torque converter (TC) of 4T65E commonly causes a lot of problems during repair procedures. Bearings is a soft spot in this transmission unit. After covering 200 thousand kilometers bearings may get damaged at any moment. The major repair of this gearbox after 150-170 thousand kilometers requires replacement of all bearings.

Issues with the differential bearing may cause the most expensive difficulties (namely, damage of the sun gear differential together with differential planet gears). Then the oil flow with metal pieces may damage the valve body (VB).The main soft spots of the 4T65E frictions are two friction packages, namely, 3rd Clutch with one-sided frictions and 2nd Clutch.

In terms of design, the VB unit of the 4T60E has a lot of differences in comparison with the solution of the 4T60E. This gearbox is also sensitive to contaminated and overheated ATF as well as damaged differential.In electrical components, solenoids have quite a short service lifespan (it is advisable to check the operability of solenoids when the mileage exceeds 150 thousand kilometers).In case of an old car overhaul with mileages strongly beyond 200 thousand kilometers, it is required to replace worn-out bushings which are commonly ordered in a complete kit.

This gearbox is reliable and not complicated. After a major repair it has a substantial resource, if drivers monitor the ATF cleanness and not overload the transmission by maximum torques.Problems mainly occur in the XC90 using the differential in its design. Volvo cars with this gearbox are not intended for driving off the road as well as on muddy roads.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	CENTURY	00-04	4 SP FWD	V6 2.5L 3.0L 3.1L
Buick	CENTURY	00-04	4 SP FWD	V6 2.5L 3.0L 3.1L
Buick	LACROSSE/ALLURE	04-09	4 SP F/4WD	L4 2.4L V6 3.0L 3.6L 3.8L V8 5.3L
Buick	LESABRE	98-05	4 SP FWD	V6 3.8L
Buick	LUCERNE	05-11	4 SP FWD	V6 3.8L 3.9L
Buick	PARK AVENUE/ULTRA	97-04	4 SP FWD	V6 3.8L 3.8L SC
Buick	REGAL	97-04	4 SP FWD	V6 3.8L SC
Buick	RENDEZVOUS APV	01-06	4 SP F/4WD	V6 3.4L 3.5L 3.6L
Buick	RIVIERA	97-99	4 SP FWD	V6 3.8L
Buick	TERRAZA	05-07	4 SP F/4WD	V6 3.5L 3.9L
Chevrolet/GM	IMPALA	00-16	4 SP FWD	V6 3.4L 3.5L 3.8L 3.9L V8 5.3L
Chevrolet/GM	LUMINA	97-01	4 SP FWD	V6 3.1L 3.4L 3.8L 3.8L SC
Chevrolet/GM	MONTE CARLO	97-07	4 SP FWD	V6 3.1L 3.4L 3.5L 3.8L 3.9L 3.8L SC V8 5.3L
Chevrolet/GM	UPLANDER	03-08	4 SP F/4WD	V6 3.5L 3.9L
Chevrolet/GM	VENTURE APV	99-05	4 SP FWD	V6 3.4L
Oldsmobile	88 ROYALE	97-99	4 SP FWD	V6 3.8L 3.8L SC
Oldsmobile	AURORA	01-03	4 SP F/4WD	V6 3.5L
Oldsmobile	INTRIGUE	98-02	4 SP F/4WD	V6 3.5L 3.8L V8 4.5L
Oldsmobile	SILHOUETTE	99-04	4 SP F/4WD	V6 3.4L
Pontiac	AZTEK	01-05	4 SP F/4WD	V6 3.4L
Pontiac	BONNEVILLE	97-05	4 SP F/4WD	V6 3.8L 4.6L
Pontiac	G6	06-09	4 SP FWD	V6 3.9L
Pontiac	GRAND PRIX	97-08	4 SP F/4WD	V6 3.1L 3.8L V8 5.3L
Pontiac	MONTANA / SV6	99-08	4 SP F/4WD	V6 3.5L 3.9L
Pontiac	TRANS SPORT	99-04	4 SP F/4WD	V6 3.4L
Saturn	RELAY	05-07	4 SP F/4WD	V6 3.5L 3.9L
Volvo	S80	99-06	4 SP FWD	L6 2.9L

How to repair this transmission (Videos)

Teardown Inspection with code P1811

Transmission Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	TransTec Manual 4T65e
pdf	www.at-manuals.com	Scheme 4T65e
web	www.at-manuals.com	Check Balls 4T65e
web	www.at-manuals.com	4T60E Solenoids
pdf	Sonnax	Valve Body Layout 4T65-E
pdf	Sonnax	Vacuum test 4T65-E

4T40E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 4T40E, 4T45E rarely appears in repair services. It has been used since 1995 on FWD American (and Korean) GM vehicles with engines up to 2 liters. In terms of design, this transmission is related to the 3T40, their spare parts are interchangeable.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	230	11,7	6,5	Dexron VI

Technical issues and repair guidelines

The repair of the 4Т40 transmission often lies in change of ATF, and replacement of filter and spare parts. The oil of any type (from Dexron III to Dexron VI) may be used for the 4Т40 transmission.

The torque converter is a soft spot in almost all American automatic transmissions and requires replacement of spare parts quite early. Driving with worn torque converter may lead to vibrations, rapid ATF contamination and issues with the seal and bushing of the torque converter located immediately near the input. If this problem stays neglected, then it is required to change the torque converter bushing and the whole kit of bushings.The problem of burnt ATF is solved by replacement of all friction elements and the brake band.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	SKYLARK	97	4 SP FWD	L4 2.4L
Chevrolet/GM	CAVALIER	95-05	4 SP FWD	L4 2.2L 2.3L 2.4L
Chevrolet/GM	LACETTI	06-08	4 SP FWD	L4 1.5L 1.6L
Daewoo	NEXIA	00-03	4 SP FWD	L4 1.5L
Daewoo	NUBIRA-2	00-04	4 SP FWD	L4 1.5L 1.6L 1.8L 2.0L
Oldsmobile	ALERO	99-04	4 SP F/4WD	L4 2.2L 2.4L
Oldsmobile	CUTLASS	97-99	4 SP FWD	V6 3.1L
Pontiac	GRAND AM	99-05	4 SP FWD	L4 2.2L 2.4L
Pontiac	SUNFIRE	95-05	4 SP F/4WD	L4 2.2L 2.4L

How to repair this transmission (Videos)

4T40E Teardown

Transmission - Teardown Inspection

4R100 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 4R100\ E4OD for powerful RWD vehicles with engine capacity from 5 liters was produced by Ford since 1996.This transmission is a modification of its predecessor E4OD, which was used since 1989.It is tested, well-balanced and rare in repair transmission. Efficient and not complicated design of this transmission served as a basis for the following generation of the 5-speed automatic transmissions - 5R110W. (starting from 2003).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	1000	16,2	8	Mercon V

Technical issues and repair guidelines

Problems with this transmission start with solenoids, reaching the end of their service life, or when the valve body gets clogged together with valves, transmitting the pressure in line. It leads to the burning of friction components or even drums.Filters for both modifications 4R100\ E4OD are the same and differ by high scoop.The kit of frictions gets fully replaced in case of burnt ATF.

In addtion to spare parts with rubber covered pistons, a typical repair order includes the brake band Intermediate (Direct, High/ Reverse). Seals of the pump and the input shaft are replaced in the course of repair of old cars.

Then transmission specialists usually deal with the following components:

- the drum Intermediate/ Overdrive Clutch

- Separator of the overrunning clutch Sprag, (INTERM).

- solenoids are replaced as a whole block.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	ECONOLINE 150	1/98-04	4 SP RWD	V8 5.4L
Ford	ECONOLINE 250/250 SUPER DUTY	1/98-04	4 SP RWD	V8 5.4L 7.3L DIESEL V10 6.8L
Ford	ECONOLINE 350/350 SUPER DUTY	1/98-05	4 SP RWD	V8 5.4L 7.3L DIESEL V10 6.8L
Ford	EXCURSION	00-05	4 SP R/4WD	V8 5.4L 7.3L DIESEL V10 6.8L
Ford	EXPEDITION	1/98-02	4 SP R/4WD	V8 5.4L
Ford	F-150 /F-250	1/98-07	4 SP R/4WD	V8 5.4L 7.3L DIESEL V10 6.8L
Ford	F-350/350 SUPER DUTY	99-04	4 SP R/4WD	V8 5.4L 7.3L DIESEL V10 6.8L
Ford	F-450/550 SUPER DUTY	3/98-04	4 SP R/4WD	V8 7.3L DIESEL V10 6.8L
Lincoln	BLACKWOOD	2	4 SP RWD	V8 5.4L
Lincoln	NAVIGATOR	1/98-04	4 SP R/4WD	V8 5.4L

How to repair this transmission (Videos)

Teardown Inspection, No 2-3 UpShift

4R100 Teardown

4R100 rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 4R100
web	Sonnax	6 Key Features to Understand in Ford E4OD, 4R100 & 5R110W

4L80E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission GM 4L80 was introduced 1990. It was used for trucks and SUVs with the engine capacity from 5 liters. This transmission is extremely reliable, powerful, and not complicated in terms of design. It has been installed on army armored vehicles Cobra and armored fighting cars Eagle for many years.The 4L80 is a famous predecessor the 3-speed 3L80. Many spare parts are interchangeable. In most cases, this transmission appears in repair services with Jaguars. It is also installed on powerful cars with engines from 5 liters including Hummer and Rolls-Royce.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/4WD	600	13,4	6,7	Dexron VI

Technical issues and repair guidelines

This transmission is a rare “guest” in repair services, thus it can be assumed that this unit is quite reliable. It went through many upgrades without serious changes (only rarely updating gaskets, seals, and filters). Clutch and brake packages are designed very reliably with such a huge reserve, that the type of friction elements hasn’t been changed since 1965.

The Direct clutch pack is the first to be worn-out and considered to be one of the weakest clutch packs. But it is quite normal and occurs after considerable mileages, extreme operating conditions and loads. If friction components of two abovementioned packs burn ATF for a long time and this ATF soaks in other friction linings, then the whole set of friction components should be replaced.

After 12-15 years of usage the wear-out of bushings becomes clear and vibrations exceed allowed limit, therefore repair specialists have to replace the whole set of bushings. Solenoids and the torque converter lock-up solenoid also reach the end of their service life by time. Almost all overhauls are performed when bushings, hollow discs, solenoids reach the end of their long service life. These transmissions easily operate for 200 thousand kilometers and even longer.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	C/K PICK-UP 1500-2500	95-00	4 SP R/4WD	V8 5.0L 5.3L 5.7L 6.0L 7.4L 6.5L DIESEL
Chevrolet/GM	VAN FULL SIZE 2500	96-09	4 SP R/4WD	V6 4.3L V8 4.8L 5.7L 6.0L 7.4L 8.1L 6.5L 6.6L DIESEL

How to repair this transmission (Videos)

Transmission repair

Teardown Inspection

Valvebody Repair and Vacuum Test

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme 4L80
pdf	Sonnax	Vacuum test 4L80-E, 4L85-E
web	Sonnax	Outsmarting 4L80-E Overdrive Roller Clutch Failure
web	Sonnax	Check Balls 4L80

4L30E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 4L30E is the successor of a reliable 3-speed transmission 3L30E, which has been used since 1969. These transmissions were made in the USA and in Europe (Strasbourg) under the name AR25 for RWD Opel Omega and AR35 for a 3-liter Katera.

The 4L30E has been installed since 1990 on RWD and AWD BMWs of all series with engine capacity of up to 3 liters, but it was more widely used on GM, Opel Omega, Isuzu and even on Honda Passport where it proved to be highly efficient.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/AWD	350	9,7	4,6	Dexron VI

Technical issues and repair guidelines

The torque converter, valve body and solenoids in the 4L30E transmission have a relatively limited resource. The operability of these components is gradually deteriorating because of the friction lock-up wear-out and accumulation of varnish in the narrowest places leading to the oil pressure drop and oil starvation, that results in a harmful impact on bushings, which have a proper resource.Operations with the worn-out pump liner and contaminated ATF lead to the oil pump damage. Plastic washer-bearings are also considered to be spare parts to be replaced.

The valve body after 200 thousand kilometers requires a statutory disassembly, repair and cleaning from varnish. The linear pressure solenoid was introduced in the valve body design for the brake band drive gear for regulation of the band pressure on the drum by means of PWM. Solenoids with exhausted resource are considered to be a typical problem in the electrical part of the transmission. The line pressure solenoid is also frequently replaced.

It is a reliable well-regulated transmission with a robust service resource for its components. After a simple overhaul this transmission can additionally operate for several years, if you properly monitor the ATF condition.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Acura	SLX	96-99	4 SP RWD	V6 3.2L 3.5L
BMW	3-SERIES	92-00	4 SP RWD	L4 1.8 1.9L L6 2.5L 2.8L
BMW	5-SERIES	90-99	4 SP RWD	L6 2.5L 2.8L
BMW	7-SERIES	00-01	4 SP RWD	L6 2.9L
Cadillac	CATERA	98-01	4 SP RWD	V6 3.0L
Honda	PASSPORT	94-02	4 SP RWD	L4 2.6L V6 3.2L
Isuzu	AMIGO	99-02	4 SP RWD	L4 2.2L V6 3.2L
Isuzu	AXIOM	02-04	4 SP RWD	V6 3.5L
Isuzu	RODEO	91-04	4 SP R/4WD	ALL
Isuzu	TROOPER	90-02	4 SP 4WD	V6 3.2L 3.5L
Isuzu	VEHICROSS	99-01	4 SP 4WD	V6 3.2L
Opel / Vauxhall	CATERA	00-01	4 SP RWD	V6 3.0L
Opel / Vauxhall	FRONTERA	00-04	4 SP RWD	L4 2.2L V6 3.2L
Opel / Vauxhall	OMEGA	00-03	4 SP RWD	L4 2.0L 2.2L 2.5L V6 2.5L 2.6L 3.0L 3.2L

How to repair this transmission (Videos)

4L30E Teardown

Band Adjustment

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual 4L30
pdf	www.at-manuals.com	Manual 4L30e

4HP20 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission ZF 4HP20 has been installed on a wide range of European FWD cars since 1995. This transmission is intended for the torque up to 330 Nm. ZF 4HP20 is used on Peugeot, Renault, Citroen with 2-3 liter engine. The 4HP20 unit has been installed on V-class Mercedes since 1998. This 4-speed transmission was used by PSA (Peugeot-Citroen) as the next modification of its AL-4 (DP0) for more powerful engines with the torque up to 330 Nm. This transmission lived up to all expectations by its dynamic characteristics and viability. It is a very reliable and low-maintenance transmission, which is mainly handed in for repair with the purpose of the filter change and replacement of gaskets and seals. The manufacturer assures that there is no need in fluid change during the first 10 years.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	330	8,3	3,5	LT 71141

Technical issues and repair guidelines

It is recommended to change fluid (Esso LT 71141) in this transmission after covering 60-80 thousand kilometers, depending on the driving style aggressiveness and transmission wear-out. The fluid level usually causes no problems, it is changed by means of partial change in several stages or complete change. The operation with insignificant fluid underfilling is also allowed, but the fluid overflow may be harmful for this transmission.

Typical problems with 4HP20:

The torque converter of the 4HP20 unit is the first component that cannot endure intensive exploitation. Initial vibrations caused by unevenly worn-out lock-up clutch lead to vibrations on the pump shaft and leakages through the seal. The next component to get out of order is the assembled oil pump. The bushing in the pump fails, forcing car owners to pay for replacement of the whole pump unit as neither bushings nor covers are supplied separately. The seal replacement without repair of the torque converter cannot solve the problem, but only buy some time.

Typical problems in electrical components of this transmission occur early and frequently. The valve body gets clogged with dirt, shavings and wear debris of friction components. In the course of the valve body repair it is quite common that some problems may occur with solenoids which exhausted their resource.

The next parts to be replaced in the 4HP20 unit are:

- Rubber-covered pistons in package F

- Piston of package D – wears out because of overheating

- Piston of package C – overheating

- Seals and piston cups of the pump and half-axle

The torque converter may have some problems when it stays neglected: wear-out of the lock-up mechanism, intended for blocking the clutch starting from the second gear. The torque converter quickly overheats and stops operating properly because of the worn-out lock-up clutch. The abovementioned factor leads to increase in fuel consumption, oil heating and pump operation, deterioration of acceleration characteristics, rapid wear-out of seals and bushings.The torque converter repair of the 4HP20 unit is more common in repair services than regularly repaired JF506, RE5R05, AXOD-E etc. But in general, this transmission is quite reliable, and when adhering to operational rules this transmission won't cause much trouble.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Alfa-Romeo	166	00-06	4 SP F/4WD	V6 3.0L
Citroen	C5	00-05	4 SP FWD	L4 2.0L 2.2L V6 2.9L
Citroen	JUMPER	00-06	4 SP FWD	L4 2.8L
Fiat	DUCATO	01-07	4 SP FWD	L4 2.8L
Fiat	ULYSSE	02-06	4 SP FWD	V6 2.9L
Ford	MONDEO	00-01	4 SP F/4WD	L4 2.0L
Hawtai	B11	11-15	4 SP FWD	L4 2.0L
Hawtai	BOLIGER	11-16	4 SP F/4WD	L4 1.8L 2.0L
Hawtai	E70	13-16	4 SP FWD	L3 1.5L L4 1.5L 2.0L
Hawtai	E90	15-16	4 SP FWD	L4 2.0L
Hawtai	NEW SANTA FE	15-16	4 SP FWD	L4 1.8L
Hawtai	SANTA FE C9	10-16	4 SP F/4WD	L4 1.8L 2.0L
Lancia	K	00-01	4 SP FWD	V6 3.0L
Lancia	PHEDRA	02-06	4 SP FWD	V6 2.9L
Mercedes-Benz	MB	02-04	4 SP FWD	L4 2.2L
Mercedes-Benz	V-CLASS	00-03	4 SP FWD	L4 2.2L 2.3L
Mercedes-Benz	VITO	00-03	4 SP FWD	L4 2.0L 2.2L
Peugeot	406/406 COUPE	00-04	4 SP FWD	V6 2.9L
Peugeot	407	03-10	4 SP FWD	L4 2.0L 2.2L
Peugeot	607	00-06	4 SP FWD	L4 2.2L V6 2.9L
Renault	SAFRANE	00-01	4 SP FWD	V6 2.9L
Zhonghua	COUPE	08-12	4 SP FWD	L4 1.8L
Zhonghua	ZUNCHI	12-16	4 SP FWD	L4 2.0L

How to repair this transmission (Videos)

Vito overhauling

4HP20 CONHECA

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual
pdf	drive.google.com	ZF 4HP20 Repair manual

4HP16 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission ZF4HP16 for was released in the early 2000-th, when its predecessor ZF 4HP20 was thoroughly tested under operational conditions. The 4HP16 unit is a reduction design copy of the4HP20 solution. ZF 4HP16 is intended for lower torque (up to 240 Nm) and mainly produced by Korean companies under the ZF licence for FWD cars such as Daewoo, Chevrolet (Lacetti), Grand Vitara etc with the engine from 1.6 up to 2 liters. This transmission is the competitor of the U240 unit.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	240	6,9	4	LT 71141

Technical issues and repair guidelines

The 4HP16 unit can be rarely found in repair shops. It it can be explained by the fact that this transmission, like all 4-speed ZF transmissions, is notable for its durablity and lack of major weaknesses. This transmission operates with different fluid types, but it is necessary to monitor the fluid level and its quality.

Repair and replacements

ATF change is accompanied by replacement of a one-time filter with a felt membrane. They are recommended for replacement after the second oil change, and for old cars – every time when changing the oil, that preserves solenoids and very expensive valve body.

Unilateral frictions usually get burnt in the clutch pack C. The responsive steel disc burns together with these friction elements. To solve this issue, ZF engineers changed the positioning of these three problematic friction discs in the following modifications. The piston is also frequently replaced during the transmission rebuilding. Spare parts in the 4HP16 unit are usually replaced in old torque converters. If this measure is neglected, then it may cause leaks in seals and the pump damage.

There are some minor problems with electrical components, which do not endure hot summer in the city and aggressive driving style with fluid overheating. Problems with contaminated solenoids lead to insufficient oil pressure resulting in problems with seals, bushings and pump with the torque converter. D and Е packages also get frequently damaged. Problems of old/worn-out transmissions (usually after 200 thousand kilometers) are similar to problems in the 4HP20 transmission.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	EXCELLE	03-09	4 SP FWD	L4 1.8L
Chevrolet/GM	EPICA	05-12	4 SP FWD	L4 2.0L
Chevrolet/GM	OPTRA	03-12	4 SP FWD	L4 1.8L
Chevrolet/GM	ORLANDO	10-11	4 SP FWD	L4 1.8L 2.0L DIESEL
Daewoo	LACETTI	02-11	4 SP FWD	L4 1.6L 1.8L 2.0L
Daewoo	LEGANZA	00-03	4 SP FWD	L4 1.8L 2.0L 2.2L
Daewoo	MAGNUS	00-03	4 SP FWD	L4 2.0L V6 2.5L
Daewoo	REZZO	00-08	4 SP FWD	L4 2.0L
Suzuki	FORENZA	04-08	4 SP FWD	L4 2.0L
Suzuki	RENO	04-08	4 SP FWD	L4 2.0L
Suzuki	VERONA	04-06	4 SP FWD	L6 2.5L

How to repair this transmission (Videos)

zf 4hp16 pictures

Zf4hp16 valve body

Zf4hp16 valve body2

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

4F27E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearbox 4F27E was designed in 1998 for well-known FWD vehicles Ford Focus with the engine capacity from 1.3 up to 2 liters. According to Mazda classification, this models is also known as FN4A-EL. This gearbox is intended for lower torque. It is a remarkable solution which can be rebuilt without removing the whole mechanism. The cover is a common component for repair in this gearbox.

This easy-to-operate gearbox is still assembled on many plants of Ford-Mazda worldwide. The range of 4F27E /FNR5 is the most common Ford-Mazda gearboxes in repair services. Spare parts for repair of 4F27E (FN4A-EL) are almost the same as in the 5-speed FNR5.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	200	8	3,5	DexronVI / Mercon LV

Technical issues and repair guidelines

Clearance of the Reverse drum on the back cover stator.

Friction components of Overdrive and Reverse packages get burnt quite rapidly. Fast burning of these elements is related to design peculiarities of such type of gearboxes. Burning of these reliable friction elements occurs because the drum seating position on the rear cover support wears out and oil leaks out from teflon rings.

Back cover of the FN4A-EL

Specialists assume that the back cover issue is related to the stator’s material in the FN4A-EL. It is softer than in Ford (4F27E), therefore gearboxes for Ford have no problems with the rear cover.

Electrical elements in the 4F27E work properly for a long time.

The valve body is usually cleaned and rubber with gaskets get replaced with the help of the Overhaul Kit.

The differential is one more problematic component of “old” units. Ford updated the differential several times for different cars and now differentials of the 4F27E vary in quantity of “teeth”.
Rubber-covered pistons (Reverse, Forward, Low/Reverse) are the spare parts of second priority.

This gearbox is well-known among repair specialists, most parts for this gearbox are widely available. Proper exploitation and well-timed maintenance make this gearbox reliable and repairable.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	ECOSPORT	07-12	4 SP FWD	L4 2.0L
Ford	FESTIVA	0	4 SP FWD	L4 1.3L
Ford	FIESTA	08-13	4 SP FWD	L4 1.3L 1.4L 1.5L
Ford	FOCUS C-MAX	00-11	4 SP FWD	L4 1.6L 1.8L 2.0L 2.3L
Ford	I-MAX	07-10	4 SP F/4WD	L4 1.8L
Ford	IXION	04-05	4 SP F/4WD	L4 1.8L
Ford	LASER	00-05	4 SP FWD	L4 1.5L 1.8L
Ford	LYNX	00-05	4 SP FWD	L4 1.3L 1.6L
Ford	TELSTAR	0	4 SP FWD	L4 2.0L
Ford	TIERRA	00-07	4 SP FWD	L4 1.6L
Ford	TRANSIT CONNECT	09-13	4 SP FWD	L4 2.0L
Hongqi	MINGSHI	06-08	4 SP F/4WD	V6 2.0L

How to repair this transmission (Videos)

FN4AEL Teardown

Ford 4F27E Auto Tranmsission Rebuild

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Failures and Faithful Fixes for FN4A-EL and 4F27E
pdf	www.at-manuals.com	Scheme 4F27E
web	www.at-manuals.com	Stall test 4F27E
web	www.at-manuals.com	Solenoid application chart 4F27E

4L60E Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed family of GM transmissions named as TH700R4 (Turbo-Hydramatic) 4L60E/ 4L65E has been launched in production in 1982 and after some minor changes was renamed as 4L60. This 4-speed transmission for RWD cars was constructively based on the popular HydraMatic 700R4, but produced at the GM factory in Toledo (Ohio) and proved to be very efficient. This gearbox was used on RWD 4WD cargo vehicles and off-road vehicles with the engine from 3 up to 6 liters. It is the primary transmission for Hammers and also was used on Suzuki Vitara and SAAB. In 1996, engineers introduced a significant update and as a result the valve body control became electronic and it was named as the 4L60-E.

But the main innovation leading to high level of sales was the solenoid-regulator allowing soft shifting of gears and fast acceleration as well as control over the torque converter (TC) lock slippery. By 2001 the enhanced version of the 4L65E had been released. This modification was intended for the torque equal to 515 Nm. The next modifications of hydraulics and electronics and were introduced in 2001 -2003.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD/4WD	488	10,8	5	Dexron VI

Technical issues and repair guidelines

The TC lock-up clutch is the first element to wear out leading to oil contamination and clogging of solenoids with sensors. The TC unit in this transmission operates quite intensively, accelerating a powerful car with the help of the lock-up when the driver strongly pushes the throttle pedal to the floor.The clutch drum and the brake band frequently turn out to be a major issue for Hammers H2 and H3 with engines over 5 liters.

The first overhauls of the 4L60 consist in cleaning of the valve body (VB) and solenoids, repair of the TC unit with replacement of the lock-up unit and some spare parts. If the ATF and filter are replaced often and in due time, then the transmission operates properly for a long time. Solenoids are replaced as a full kit when their operating period comes to an end.

After covering 150-200 thousand kilometers the following units fail due to the transmission ageing (and first of all because of contaminated oil):

- Valve body separate plate

-Separator of the overrunning clutch, Forward (Input) Clutch and Low/Reverse.

Intensively operating rear planetary gear is usually replaced on old cars. The kit of valve body gaskets is one of the most frequently ordered spare parts. The kit of bearings is also ordered for the transmission reassembly. In general, these automatic transmissions are robust and consistent and after a standard overhaul they will serve for a long period of time.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	C/K PICK-UP 1500-2500-3500(95)	95-97	4 SP R/4WD	V6 4.3L V8 4.8L 5.0L 5.3L 5.7L 6.0L
Chevrolet/GM	VAN FULL SIZE 1500-2500	95-11	4 SP RWD	V6 4.3L V8 4.8L 5.0L 5.3L 5.7L 6.5L DIESEL
Chevrolet/GM	VAN FULL SIZE 3500	95-99	4 SP RWD	V6 4.3L

How to repair this transmission (Videos)

Gear Train Removal and Inspection

Valvebody and Pump Disassembly

Reverse Input Drum and Input Clutch Assemble

Reassembly of Pump and Gear Train

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Transmission scheme 4L60
web	www.at-manuals.com	Solenoids 4L60E
web	www.at-manuals.com	4L60/4L65E components
pdf	www.at-manuals.com	Scheme 4L60
pdf	www.at-manuals.com	Rebuild manual 4L60e
pdf	www.at-manuals.com	Repair manual 4L60e
pdf	www.at-manuals.com	Turning a 4L60E into a Manually Shifted Trans
pdf	Sonnax	Vacuum test 4L60-E, 4L65-E, 4L70-E
pdf	Sonnax	Recognize & Repair Solenoid Accumulators in Late-Model Valve Bodies
web	Sonnax	BUILD THE KILLER 4L60-E
web	Sonnax	4L60-E Valve Body Identification Guide
video	Sonnax	Guide to a Sonnax 4L60/E Level 3 Performance Build

4HP14 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission ZF 4HP14 found application on compact cars produced by Peugeot and Citroën, later it was installed on Daewoo models. This successful transmission also operated and on Volvo and Saab cars with engine capacity up to 2 liters. The main improvements in this transmission were implemented in 1986, and in 1989. Since then, the 4HP14 design hasn’t been seriously changed.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		5,4	2,5	Dexron III

Technical issues and repair guidelines

The main maintenance requirement for this transmission during many years of reliable service is timely ATF change (Dexron III or Dexron VI) and fiilter replacement every 100 thousand kilometers. The torque converter unit of this transmission easily operates for 200 thousand kilometers without any repair. There is no much information related to the repair of hard parts of the ZF 4HP14 unit to draw some patterns, because this transmission operates properly for a long time and the car gets too old before the first transmission overhaul.

The most popular parts ordered for the overhaul of this transmission are the following:

- filter

- Repair kit of gaskets and seals (Overhaul Kit),

- brake band

- pump bushing (or turbine shaft bushing) and friction clutches

In most cases, repair specialists have to repair frictions in the Forward pack and steel discs. The kit of steel discs is ordered not so often for repair, because friction components wear out rather than get burnt.Seal, pump, and turbine shaft bushing are the first to get burnt because of vibrations and overheating of the worn-out torque converter.

In all other respects, this transmission is quite simple and almost problem-free. After the valve body cleaning, the torque converter reassembly, and proper repair this gear shifting unit becomes extremely robust.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	AVEO	04-16	4 SP FWD	L4 1.6L
Chevrolet/GM	LANOS	05-09	4 SP FWD	L4 1.4L 1.5L 1.6L
Chevrolet/GM	VIVA	11	4 SP FWD	L4 1.6L
Daewoo	LANOS II	00-03	4 SP FWD	L4 1.4L 1.5L 1.6L
Fiat	PALIO	04-07	4 SP FWD	L4 1.5L
Fiat	SIENA	04-08	4 SP FWD	L4 1.5L

How to repair this transmission (Videos)

4 hp 14 volvo

BVA 4HP14 Citroën

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme

AX4N Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission AX4N was designed in 1994. It is the modification of its predecessor AX4S, which is in turn the modification of the AOD-E transmission.This transmission was not very popular and since 2004 it had been frequently replaced by German CVT CFT30 and the 6-speed transmission AF21 (TF-81SC) until 2007 when Mazda produced the 6- speed 6F50, and later (2009) - the enhanced 6F55.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	370	12,8	6,6	Mercon V

Technical issues and repair guidelines

The most popular spare parts rebuilding of this transmission are the following: repair kit of gaskets and seals (Overhaul kit). For all transmissions of this family installed on old cars, it is recommended to change ATF (Mercon V - Dexron-IV) with the filter each year after operation in hot summer time. It is required to check the ATF state for transparency. In many cases, problems of the AX4N are related to inconveniences in gears shifting caused by shortcomings of the valve body design, which gets clogged by friction dust.

Many specialists assume that the main reason of ATF contamination is the torque converter. The torque converter overheats ATF and facilitates to rapid oil contamination by friction wear debris, which quickly damage the valve body material. The manufacturer recommends installation of an additional transmission radiator.

Spare parts of the AX4N are sensitive to extreme operating conditions and as a result it leads to fast wear-out of all wearing elements, including brake bands Rear -Coast and O.D. - Overdrive, rubber-covered pistons. In the course of the transmission reassembly, it is recommended to check properly all rubber elements for elasticity of the rubber protection shield. The first compenents to get burnt are friction elments of the Direct package, and later Forward package. Other friction components wear out more rarely and often left untouched till the next overhaul.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	FREESTAR	04-07	4 SP FWD	V6 3.9L 4.2L
Ford	TAURUS	01-07	4 SP FWD	V6 3.0L
Ford	WINDSTAR	01-03	4 SP FWD	V6 3.8L
Lincoln	CONTINENTAL	95-02	4 SP FWD	V8 4.6L
Mercury	MONTEREY	03-06	4 SP FWD	V6 4.2L

How to repair this transmission (Videos)

AX4N Teardown Inspection, Part one

AX4N Teardown Inspection Part 2

AX4N Teardown Inspection Part 3

AX4N with code P0741

AX4N taking it apart

Instruction manuals and useful links

Link type	Source	Description
web	www.at-manuals.com	Scheme AX4N
0	Sonnax	Valve Body Layout AX4N, 4F50N

G4AEL Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The first Mazda's 4-speed automatic transmission G4A-EL was designed with partial electronic controlling mechanism (shift solenoids). This transmission was used on Mazda 626 since 1987. In 1989, after thorough testing and updating this great transmission found application in Ford Probe. According to Ford classification, named as 4EAT-G.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	230	6,8	3,5	Dexron III

Technical issues and repair guidelines

This transmission operates with different types of ATF manufactured by famous brands. It is recommended to change ATF only after estimation of its condition, and the older the car - the more frequently it is required to change ATF. In many cases, the torque converter lock-up wear-out clogs the valve body and damages solenoids. That leads to the torque converter repair and replacement of related spare parts.Complete reassembly of the transmission is performed with the help of Masterkit repair kit. This kit includes all gaskets and seals, all friction components and clutch discs. In terms of design, this transmission is similar to the F4A-EL (4EAT-F) and has the same common repair issues.

Every third repair of this transmission is minor and lies in replacement of the torque converter seals and gaskets (pan, pump and side valve cover) from oil leakage. At the same time specialists usually repair the torque converter with replacement of worn-out friction lining. The wear-out of the valve of linear pressure solenoids (EPC) and of the torque converter lock-up also causes many problems (jolts when shifting) in the GF4A-EL/ FU9A transmission.

Vibrations and rapid wear-out of bushings and seals start in case of a long oil starvation, which is usually related to the torque converter overheating, dirty valve body and solenoids. The brake band is one of typical spare parts, its successful design has not been changed since 1988. The drum Overdrive G4AEL 3-4 CL 42mm Overall Height (52,38mm OD Neck) 1986-2002 gets burnt together with clutches. Oil starvation leads to wear-out of friction surfaces. Repair specialists usually replace several essential gaskets and seals. The list of relevant spare parts also includes pan gaskets and the side cover gasket.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Ford	PROBE	90-93	4 SP FWD	L4 2.2L V6 3.0L

How to repair this transmission (Videos)

Transmission Failure Mazda

Ford F-4EAT

Replacement Auto Transmission

rebuild Fix Part 2 of 3

Failure Fix Part 3 of 3

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme G4AEL
web	www.at-manuals.com	Clutch application G4AEL
web	www.at-manuals.com	Valve body G4AEL

F4AEL Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission F4A-EL (KIA - 4EAT-F, F4E-AT) was designed by Mazda specialists together with Jatco in 1989 for FWD vehicles with the engine capacity of approx. 1.6 liters. This transmission had to replace the 3-speed F3A and was used for Mazda 323 and Ford Escort. In terms of design, this transmission is similar to the 4EAT-G.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	150	7,8	3,5	SP-III

Technical issues and repair guidelines

This reliable and simple automatic transmission in most cases comes in repair services with the torque converter issues and replacement of spare parts: repair kit of gaskets and seals. Friction elements of Forward, Overdrive 3-4 and Reverse packs are the first to get burnt because of wear-out of rings and bushings. Later, repair specialists packages Coast and L\R. With transmission aging it is required to replace the kit of bushings. Significant oil pressure losses and burning of friction elements in packages occur, when the wear-out of bushings exceeds 100 microns. The bushing of the torque converter hub is the first to wear out.

The clutch drum (Reverse & Forward Clutch Drum (only for Ford/Mazda)) gets replaced together with burnt friction elements, steel and bearing discs on old cars.Operation with contaminated ATF and vibrations related to wear-out of bushes has a bad impact on the oil pump. The rear cover is also replaced quite often (poor Y-alloy in Mazda). The valve body of this transmission has a specific distinction: for Kia- there is a valve 3-2, for Ford and Mazda- no valve. A new design of the valve body is very robust and has no problems of the first series. Timely detection of the burnt flavor and cleaning of the valve body with replacement of the EPC solenoid (or SHIFT - Ford/Mazda), 2-3 и 3-4.), which reaches the end of its service life, ensure reliability and a long-time service life of this transmission without any serious problems.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Mercury	TRACER	90-99	4 SP FWD	L4 1.8L 1.9L 2.0L

How to repair this transmission (Videos)

Kia Spectra Transmission

F4A-EL Case Lugs

1998 Escort Transmission

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Scheme F4AEL
web	www.at-manuals.com	TransTec Manual F4AEL
web	www.at-manuals.com	Stall test F4AEL

4EAT Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission Subaru 4EAT was manufactured in 1988 (EC8 = R4AX-EL). This transmission is related to the F-4EAT transmission model manufactured by Jatco. The modification released in 1999 was replaced the previous EC8 version on almost all popular Subaru models. This transmission was installed not only on low-powered Impreza and WRX, but also on middle class Forester and Outback with 2-2,5 liter engines, and even on powerful Legacy model with the engine capacity of 3 and 3.5 liters.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	300	9,5	6	Dexron III-VI / Mercon V

Technical issues and repair guidelines

Subaru vehicles with this transmission rarely come to transmission repair shops. In terms of maintenance services, this transmission is very similar to Jatco transmnissions. The 4EAT unit is a very reliable and simple system with special settings which do not allow drivers to overload prone-to-damage parts with a high degree of safety.

Overhauls usually consist of the reassembly procedure with replacement of the filter and repair kit of gaskets and seals. A kit of friction components is also commonly ordered by transmission specialists together with the abovementioned components. If the transmission operates for a long time with burnt fluid, then all steel discs get replaced with frictions. The external filter protects the valve body and solenoids from contaminated ATF, which appears because of the worn friction lining of the torque converter. Specialists recommend to replace it together with the engine oil filter on cars where the mileage parameter enxceeds 100 thousand kilometers, especially after a hot summer. The valve body unit of this transmission was updated in 1998 (type 2) and in 2001. These components are quite durable and require only timely cleaning.

If the transmission is overheated and has leakages through the pump seal of the torque converter and oil rapidly gets contaminated after the ATF, then the torque converter lock-up clutch is likely to wear out, and as a result damages the wheel hub. The torque converter is repaired and the valve body gets cleaned from the dirt, which appears from the damaged friction, and the overhaul kit is replaced. The first standard overhaul of the car with high mileage always includes replacement of pistons with frictions and a solenoid of linear pressure. The resource of this transmission is above the average and after a proper overhaul may be increased for several years.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Saab	9'2X	04-06	4 SP F/4WD	L4 2.0L 2.5L
Subaru	BAJA	03-06	4 SP 4WD	H4 2.5L H6 3.0L
Subaru	DEX	08-10	4 SP F/4WD	H4 1.3L
Subaru	FORESTER	98-12	4 SP 4WD	H4 2.0L 2.5L
Subaru	IMPREZA / WRX	93-11	4 SP 4WD	H4 1.5L 1.6L 1.8L 2.0L 2.2L 2.5L
Subaru	LEGACY	90-10	4 SP 4WD	H4 2.0L 2.2L 2.5L H6 3.0L 3.6L
Subaru	LOYALE	88-90	4 SP 4WD	H4 1.8L
Subaru	OUTBACK	00-10	4 SP 4WD	H4 2.5L H6 3.0L
Subaru	SVX	92-97	4 SP 4WD	H6 3.0 3.3L
Subaru	XT	87-91	4 SP RWD	H4 1.8L 2.7L

How to repair this transmission (Videos)

4EAT rebuilding

4eat transfer clutch

Servicing a Subaru Phase II 4EAT

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Manual
pdf	www.at-manuals.com	Repair manual
pdf	www.at-manuals.com	Scheme

A518 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The A518 was updated to 46RH (retainer hydraulic) and later to 46RE (retainer electronic). A618 was modified to 47RE and 48RE.

The family of 4-speed automatic transmissions "TorqueFlite" - A518/ A618 has been installed on rear-driven Dodge and Jeep with engines capacity about 6 liters (for A618 up to 8 liters) since 1990. This transmission is based on design of its predecessor А500.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD	610	13,4	4,8	Mopar ATF+4

Technical issues and repair guidelines

Filters for these automatic gearboxes are one-time-use with a felt membrane. With the mileage higher than 100 thousand kilometers, it is recommended to change filters with ATF. These transmissions are not very sensitive to oil type and its level, but with age oil cleanness has a greater significance for this transmission.In addition to the filter, specialists order the repair kit of gaskets and seals for the overhaul. In most cases, friction components are not ordered separately (if the oil has burning smell), but as a whole kit of frictions, which vary in years of manufacture. The kit of steel discs is ordered as well.The complete kit of spare parts Masterkit is ordered in roughly half the cases.

Popular parts to be repaired in A518/ A618:

Friction clutches and steel discs Direct and Forward operate more intensively than others and as a result get burnt. Frictions penetrated with burnt oil from the discs should be replaced.
The brake band (Reverse) is a spare part and should be replaced as often as the kit of friction componens. The list of spare parts also includes plastic discs-washers.

The electric part of the transmission exhausts its resource because of operation in overheated and contaminated ATF. Basically, controlling problems occur in the torque converter lock-up solenoid because of hot and contaminated ATF.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	DURANGO	98-03	4 SP R/4WD	V8 5.9L
Dodge	PICKUP/DAKOTA	98-00	4 SP R/4WD	V8 5.9L
Dodge	PICKUP/RAM 1500-3500	95-02	4 SP R/4WD	V8 5.2L 5.9L
Dodge	VAN/WAGON 1500-3500	95-03	4 SP RWD	V8 5.2L
JEEP	GRAND CHEROKEE	98	4 SP R/4WD	V8 5.9L

How to repair this transmission (Videos)

46RE Class introduction

46RE Class Part 1 Lesson 1

46RE Class Part 2 lesson 3

46RE Class Part 2 lesson 4

46RE Class Part 2 lesson 5

46RE Class Part 2 lesson6

46RE Class Part 2 lesson 7

48-RE Transmission - Valve Body Kit installation

46RE, 48RE transmissions

a518 transmission part 1

a518 transmission part 2

a518 transmission part 3

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout 46RH
pdf	Sonnax	Vacuum test 46RE, 46RH, 47RE, 47RH

45RFE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 45RFE was produced in 1999 for powerful 4.7 liter engines of Jeep and pickups Dodge Dakota. Subsequently, this transmission was adjusted for diesel engines (with the capacity equal to 2.8 liters). The 5-speed modification 5-45RFE has been manufactured since 2003.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		11	5	Mopar ATF+4

Technical issues and repair guidelines

These comparatively “invincible” transmissions in most cases come to repair shops for change of the oil and filters, which are replaced with dismounting of the pan. AWD modifications of this transmission have different oil filter and pan depth.

Scheduled overhaul includes the following spare parts in repair kits:

- Kit of gaskets and seals is replaced because of worn-out rings and valve body spare parts.

- Kit of friction components

- Kit of steel discs

These 3 kits compose the Master Kit. The kit of rubber-covered pistons is also ordered in case of the transmission overheating. Worn-out bushings also get replaced quite frequently.

Problems of these automatic transmissions occur when the valve body provides insufficient quantity of ATF. Solenoids also exhaust their limited service resource, the valve body gets clogged and wears out.The pump has 3 gears which are tested for wear and damages of operating surfaces. The pump bushing is also checked for wear. The pump has some issues with the wear-out of surfaces. The reason lies in a long-term operation with contaminated oil.The rubber-coated pump cover performs functions of the pump seal. This cover gets damaged by vibrations from the worn-out torque converter lock-up. There are several modifications of this cover.

Friction components with steel discs are the first to get burnt in Overdrive and Underdrive packages.This overheating of frictions in chain order leads to overheating of the valve body itself and electronics in the block of solenoids.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Dodge	DURANGO	00-02	4 SP R/4WD	V8 4.7L
Dodge	PICKUP/DAKOTA	00-02	4 SP R/4WD	V8 4.7L
Dodge	PICKUP/RAM 1500	02-05	4 SP R/4WD	V6 3.7L V8 4.7L
JEEP	GRAND CHEROKEE	99-00	4 SP R/4WD	V8 4.7L
JEEP	LIBERTY	2	4 SP R/4WD	V6 3.7L

How to repair this transmission (Videos)

45RFE Transmission Teardown Inspection

545RFE Teardown

45RFE Valvebody Overhaul

Instruction manuals and useful links

Link type	Source	Description
pdf	Valve Body Pro	45RFE Simplifying Sol's Codes
pdf	Sonnax	Valve Body Layout 45rfe
pdf	Sonnax	Vacuum test 45RFE, 545RFE, 65RFE, 66RFE, 68RFE

42RLE Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission 42RLE was designed jointly with 42LE (front-drive) and was produced since 2003, installed on the powerful RWD Chrysler of the 300-series, Liberty Jeeps, Cherokee (V6 and V8) and Dodge pickups with engines from 2.7 l up to 4 liters.

In terms of design, the 42RLE is a simplified rear-driven version of the FWD A606 (42LE), which doesn’t have the differential, chain and some other elements for the front drive.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		11	4	Mopar ATF+4

Technical issues and repair guidelines

The common repair kit for this transmission includes the following:

- repair kit of gaskets and seals.

- kit of friction components.

- kit of steel discs (less frequently)

This article covers the common issues with the Jeep Wrangler 42RLE Automatic Transmission, as well as some possible solutions. - Some of the more common problems include failed gear shifts, clutches and faulty torque converters, as well as sporadic torque converter clutch overdrive engagement problems. These issues can often indicate transmission problems which may require a rebuilt transmission. In some cases, a brand new transmission may be necessary. Older Jeep vehicles are especially prone to failure problems due to their age, and any indications of severe transmission problem should be addressed immediately. Symptoms such as loss of speed or torque converter speed can indicate a valve body issue which is a widespread issue in newer Jeep Wrangler vehicles.

This is when the transmission slips and may even cause your car to lose transmission fluid. This could be due to a faulty connection or the torque converter, which is what causes the transmission engine to slip. A slipping transmission can cause fault codes to appear on your vehicle's diagnostic scanner and indicate that you need repair. To fix this issue in a Jeep Wrangler, you will need to give your transmission a full flush and replace the valve body with a new one. This should stop your vehicle from slipping as it did before.

Causes of most transmission problems in a Jeep Wrangler can be traced to low fluid levels, leaks and lack of proper maintenance. Checking the fluid level in the transmission is one of the most common Jeep Wrangler problems. If the fluid level is too low, it can cause your car to slip or jerk as you shift gears. To avoid this problem, make sure to check your car's transmission fluid level regularly and top it off when needed. It is also important to get your car serviced regularly and use the right tools and experience to lessen transmission fluid loss due to leakages. Cars are unlike motors, so regular oil changes may not solve their problems; instead, you need to check their transmission fluids.

Automatic transmissions can be tricky and can cause a variety of problems. 42RLE Automatic Transmission Problems and Repair Solutions involve understanding the system, diagnosing the issue, and finding the right repair shop to fix it. Common problems include a transmission that tends to shift too hard or grinds when shifting. Many Dodge Ram owners experience problems in second gear where they enter a limp home mode and can only go up to 40 mph. To fix this, you may need to go to a repair shop and have your transmission flushed or replaced.

The 42Rle Automatic Transmission is found in some Chrysler vehicles and has been known to cause problems with shifting, dropping vehicle speed, and poor fuel economy. To operate the torque converter clutch, the transmission must first lock it in place. Once it is locked, the transmission will then disengage the clutch to help improve fuel economy when accelerating at certain speeds. If this does not work, you may need to unlock the torque converter clutch manually. The manual pdf that describes how to do this can be found online.

The torque converter lock-up wear-out usually results in vibrations and wear of the pump bushing (which is the same in A604-A606 and is included in the kit of bushings). The problem with the pump bushing manifests itself in leakages through the pump seal. If this problem stays neglected, then it may lead to the oil pump replacement.

The block of solenoids in the 42RLE is a common reason for many issues in this family of automatic transmissions. The resource of this block is not a large one, and the ТСМ unit loads solenoids quite intensively forcing the torque converter locking at the first opportunity to increase acceleration characteristics of the car.

The Clutch Hub (2-4 Clutch) is a typical vulnerability of these transmissions. In terms of design, this automatic gearbox has problems with the hub and a sun gear. The problem is also provoked by shortages of the oil pressure.Sensor Output Speed (VSS) and Input (TSS) cannot endure high temperatures and oil contamination by the metal dust. Pump bushings, gaskets, pistons, planetary gears get out-of-service because of insufficient oil pressure. These typical problems also occur in the family А604-А606.

This reliable transmission may serve for a long time. But it should be kept in mind that engineers of Chrysler wanted to win the competition with other fast automatic transmissions, therefore they adjusted TCM settings in such a way that the accelerator pedal easily forces the transmission work 101% of its capabilities without leaving any reserves.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chrysler	300 SERIES	04-10	4 SP RWD	V6 2.7L 3.5L
Dodge	CHALLENGER	08-11	4 SP RWD	V6 3.5L
Dodge	CHALLENGER	08-14	4 SP RWD	V6 3.5L
Dodge	CHARGER	05-10	4 SP RWD	V6 2.7L 3.5L
Dodge	DURANGO	04-08	4 SP R/4WD	V6 3.7L
Dodge	MAGNUM	04-08	4 SP RWD	V6 2.7L
Dodge	NITRO	07-11	4 SP R/4WD	V6 3.7L
Dodge	PICKUP/DAKOTA	03-11	4 SP R/4WD	V6 3.7L
Dodge	PICKUP/RAM 1500	06-16	4 SP RWD	V6 3.7L
JEEP	CHEROKEE	03-14	4 SP 4WD	V6 3.7L
JEEP	CHEROKEE	00-13	4 SP R/4WD	L4 2.4L 2.5L L6 3.6L 3.7L 4.0L
JEEP	LIBERTY	03-12	4 SP R/4WD	L4 2.4L V6 3.7L
JEEP	WRANGLER	06-16	4 SP R/4WD	V6 3.8L
JEEP	WRANGLER UNLIMITED	06-16	4 SP R/4WD	L4 2.8L V6 3.8L
Mitsubishi	ENDEAVOR	03-10	4 SP R/4WD	V6 3.8L
Mitsubishi	RAIDER	06-08	4 SP R/4WD	V6 3.7L

How to repair this transmission (Videos)

42RLE Teardown

42RLE/VLP Valvebody Overhaul & Install

Instruction manuals and useful links

Link type	Source	Description
pdf	ATRA	42RLE ATRA Technical Bulletin
web	wikipedia	Wikipedia article about 42RLE
web	Sonnax	42LE, 42RLE Variable Line Pressure

A500 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

Since 1988, the automatic transmission A500 had been installed on different models of Dodge pickups. After its modification in 1994 and renaming as 42RE (as electrically controlled transmission), it became used on famous Jeeps with the engine capacity equal to 4 liters and higher.

The 4-speed enhanced modification of 44RE named as A500 was developed for engines with a high torque (5-liter petrol-powered and 3-liter diesel engines). In terms design, this transmission is related to the TF6 (A904), and was installed on RWD vehicles and Mitsubishi pickups.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	RWD		11,6	4,5	Mopar ATF+4

Technical issues and repair guidelines

Repair kits of gaskets and seals and frictions are frequently ordered for repair of this transmission.The contamination of ATF and the valve body starts with wear-out of the torque converter lock-up. The torque converter rebuilding is recommended without waiting until the friction component damage to the glue layer.This family of RWD automatic transmissions allows drivers to use its capacity to the fullest and operates for a long time without the overhaul.

Because of transmission ageing, wear-out of the torque converter clutch (repair of the torque converter and friction replacement) and related to it overheating and oil starvation, specialists order the following parts:

- pump cover bushing

- pump seal

- Brake bands Kickdown and Reverse also considered to be "spare parts" and get replaced almost during each overhaul of an old vehicle.

The oil starvation often occurs because of problems with clogged valve body channels or as a result of improper operation of electric regulators and sensors. And it’s a consequence of a long-term exploitation with overheated and contaminated oil, caused by the worn-out torque converter lining. Torque converters on these transmissions should be repaired to prevent problems after covering 120-150 thousand kilometers.

Typical orders for the electirc part of the transmission:

- governor pressure sensor;

- ЕРС solenoid;

- block of solenoids;

- planetary gear (Front);

Specialists also frequently replace the Central support

- Gear selector is also ordered quite often for replacement.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Aston-Martin	VANTAGE	98-00	4 SP RWD	V8 5.3L
Dodge	DURANGO	98-02	4 SP R/4WD	V6 3.9L
Dodge	PICKUP/DAKOTA	95-03	4 SP R/4WD	V6 3.9L
Dodge	PICKUP/RAM 1500	95-02	4 SP R/4WD	V6 3.9L
Dodge	VAN/WAGON 1500-2500	95-96	4 SP RWD	V6 3.9L
JEEP	CHEROKEE	00-03	4 SP R/4WD	L6 4.0L
JEEP	GRAND CHEROKEE	94-04	4 SP R/4WD	L6 4.0L

How to repair this transmission (Videos)

A500 Rebuild Introduction

Part 1 - Tear Down

Part 2 - Valvebody Rebuild

Part 3 - Pump, Forward and Rear Clutch Rebuild

Part 4 - Bushing Replacement, Planetary Gear Train Rebuild

Part 5 - Overdrive Unit Rebuild

Part 6 - FINALE : Reassembly

Instruction manuals and useful links

Link type	Source	Description
pdf	Sonnax	Valve Body Layout 42RE

A606 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic transmission A606 is a modification of the A604 designed for FWD vehicles with a longitudinally positioned engine. It was designed in a couple of years after the release of its predecessor А604 (in 1993), and after two years of testing this model hit the market. In 1998, one more upgrade of this transmission was introduced with enhancement of the Reverse package and rings. According to athe new classification of Chrysler, the name of this automatic transmission (after 2003) was 42LE and this modification gained popularity.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		9,4	4,3	Mopar ATF+4

Technical issues and repair guidelines

This transmission is intended for engines with the capacity up to 3.5 liters. Many parts for this transmission are interchangeable with components from the А604. It was installed on Dodge, Chrysler, Mercury with 3 - 3.5 liter engines. A new differential and a chain were added.

Repair kits of gaskets and seals for A606 are not interchangeable with the one used for the A604. These kits are ordered almost for each repair and replacement of worn-out rings and overheated, hardened or cracked seals. Kits of friction components are universal and can be used for both transmissions. They are fully replaced, if burnt ATF reaches worn-out friction linings.The main problem of the electric part in both transmissions is the same – clogged valve body and block of solenoids. The block of solenoids for the A606 is reassembled with the use of repair kit (from the overhaul kit).

- RPM sensors are replaced

- Switch is replaced frequently (problem is caused by overheating.

Transmission components in “old” cars with the mileage higher than 200 thousand kilometers can not endure loads – in cars with powerful engines the following parts are replaced:

- Planetary gear

- Hub for frictions with a sun gear, (2-4 Hub w/Sun Gear).

- Hub for frictions (A604 Hub,Overdrive Clutch)

Steel discs burn together with friction clutches of the package Overdrive. Then burns their piston. The reason of this problem lies in the block of solenoids or worn-out bushings leading to the oil starvation in the package OD. Another typical problem of American automatic transmissions is the torque converter, which is very sensitive to even the slightest oil shortage. The planned rebuilding of the torque converter shouldn’t be postponed, if it is need.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chrysler	300M	99-04	4 SP FWD	V6 2.7L 3.5L
Chrysler	CONCORDE	95-04	4 SP FWD	V6 2.7L 3.2L 3.3L 3.5L
Chrysler	LHS	95-01	4 SP FWD	V6 3.5L
Chrysler	NEW YORKER	95-96	4 SP FWD	V6 3.5L
Chrysler	PROWLER	01-02	4 SP RWD	V6 3.5L
Dodge	INTREPID	95-04	4 SP FWD	V6 2.7L 3.2L 3.3L 3.5L
Eagle	VISION	95-97	4 SP FWD	V6 3.3L 3.5L
Plymouth	PROWLER	97-02	4 SP FWD	V6 3.5L

How to repair this transmission (Videos)

A606 Teardown Inspection

42RLE/VLP Valvebody Overhaul & Install

42RLE Teardown

42RLE New Tool for 4x4 Units

Chrysler 42LE Transaxle

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Manual A606
pdf	www.at-manuals.com	Repair manual A606
pdf	www.at-manuals.com	Scheme A606

A604 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 4-speed automatic gearbox A604 also named as "UltraDrive" (40TE/ 41TE) was designed in 1989 for front-wheel drive Chrysler vehicles and Dodge with engines ( 2-4 lit.). The structural design of the mechanical part of this transmission is based on well-known range of 3-speed gearboxes А404 - А413.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD		8,6	3,8	Mopar ATF+3

Technical issues and repair guidelines

The A604 transmission is one of the first gearboxes with added electronic computer responsible for all automatics of the hydraulics control, which adapts to the driving style and enhancing efficiency of operation of all transmission elements, including the torque converter (TC). Many spare parts can be replaced by parts for A606 (42LE) produced in 1993. In 2003, the A604 was updated one more time and renamed to 40ТЕ (for engines up to 2.4L), enhanced and well-known 41TE (up to 3.8 L).

For scheduled major repairs specialists usually include: filter, repair kits of gaskets and seals and frictions.

Typical problems are related to:

-Rear planetary gear

- Rear sun gear (wear-out of gears spline connections)

- Hub for friction clutches 2-4 with a sun gear.

- The set of hollow discs is replaced (reason: overheating, vibrations, ageing, contaminated oil with metal parts from shafts.

- The set of bearings is also replaced quite frequently.

The TC has a short operating resource. It should be handed in for repair with cutting and welding after 100-120 thousand kilometers (especially on powerful vehicles). The operation with the worn-out TC lock-up leads to beats and vibrations resulting in breakdown of the bushing and the pump seal.Typical repair of the “old” А604 consists of change of all bushings. This problem occurs when vibrations wear out bushings and oil dropping through bushings lead to the oil starvation.

Old automatic gearboxes have some issues with:

- Replacement of shaft rotation sensors

- Switch\ range sensor.

- different problems with differential bearings

- Rubber-covered piston

- Drum

This transmission reliably operates for a long period of time under the condition of yearly (or after 30 thousand kilometers) oil change and monitoring of its level and quality. If the oil is contaminated very rapidly, then it is advisable to check the TC operation and repair it on a timely basis.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Plymouth	GRAND VOYAGER	97-98	4 SP 4WD	V6 3.8L

How to repair this transmission (Videos)

41TE transmission with housing damage

604 Teardown Inspection

repair part 1

repair part 2

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Repair manual A604

3T40 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 3-speed automatic transmission GM 3T40 named as Turbo-Hydramatic 125C was installed on FWD cars with engine capacity from 2 up to 3.1 liters. The first modifications of this transmission did not have the torque converter, later versions (1995) had an electronic control and letter E was added to a new name GM 3T40E. The most significant modification was introduced in 1984. Since then sets of gaskets and seals have not been changed.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD	250	8,5	3,8	Dexron III

Technical issues and repair guidelines

The GM 3T40 is a reliable, simple transmission that operates over 300 thousand kilometers. It served as a prototype for the 4-speed family 4T40E -4T60E.This transmission rarely gets in repair services. The main spare parts ordered for repair of this transmission are the repair kit of gaskets and seals (Overhaul kit) or a complete Masterkit (with clutches and seals).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Buick	CENTURY/CENTURY WAGON	95-96	3 SP FWD	L4 2.2L
Buick	SKYLARK	95	3 SP FWD	L4 2.3L
Chevrolet/GM	BERETTA/CORSICA	95-96	3 SP FWD	L4 2.2L
Chevrolet/GM	CAVALIER	95-01	3 SP FWD	L4 2.2L
Chevrolet/GM	LUMINA	95	3 SP FWD	V6 3.1L
Oldsmobile	ACHIEVA	95	3 SP FWD	L4 2.3L
Oldsmobile	CUTLASS CIERA/CRUISER	95-96	3 SP FWD	L4 2.2L
Oldsmobile	SILHOUETTE	95	3 SP FWD	V6 3.1L
Pontiac	GRAND AM	95	3 SP FWD	L4 2.3L
Pontiac	SUNFIRE	95-02	3 SP FWD	L4 2.2L
Pontiac	TRANS SPORT	95	3 SP FWD	V6 3.1L

How to repair this transmission (Videos)

Valvebody Service and Seals

Disassembly and Inspection

Bushing Replacement and Painting

Instruction manuals and useful links

Link type	Source	Description
pdf	shop.ukrtrans.biz	Manual ATSG 3T40, 125C
pdf	shinseiauto.com	Transmission breakdown illustration 125C
pdf	at-manuals.com	Diagnosis and general service 125C
web	Sonnax	GM 125C Checkball Locations

3L80 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

3-speed automatic gearbox THM (Turbo Hydromatic) 400, also named as 3L80). Turbo-Hydramatic is a patented name for the family of automatic gearboxes designed and produced by GM.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	RWD	340	12	5	Dexron III

Technical issues and repair guidelines

This gearbox 3L80 has a simple and reliable design. All parts are made of solid materials. Shifting of gears is implemented very smoothly and almost unnoticeable. The main disadvantages of this automatic transmission are significant dimensions and weight of the transmission. This transmission is considered to be the most reliable in the history of GM (the most enduring).

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chevrolet/GM	H1 HUMMER	92	3 SP 4WD	V8 6.2L DIESEL

How to repair this transmission (Videos)

3L80 aka Turbo Hydramatic 400 tear down

Transmission Rebuild

Instruction manuals and useful links

Link type	Source	Description
web	Wikipedia	Super Turbine 400 / THM400 / THM375 / 3L80 / 3L80HD
pdf	Makcotransmissionparts	Transmission breakdown illustration
web	Sonnax	Setting Total Endplay to Prevent TH400 Gear Train Failure

A413 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This popular family of 3-speed automatic transmissions A404 / A413 / A470 / A670 had been successfully installed since 1981 on FWD vehicles Chrysler, Dodge and Plymouth of a middle class for nearly 20 years.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
3	AT	FWD		8,4	3,8	Mopar ATF+3

Technical issues and repair guidelines

The overhaul kit of gaskets and seals is frequently ordered by transmission specialists for repair of automatic gearboxes of this family. Specialists also order a complete kit of frictions. Friction components are replaced if the ATF has burning smell and its hard to set clearances in packages. A typical repair procedure of this transmission family includes the replacement of all spare parts (including the kit of friction components, steel discs and brake bands.Ageing process and overheating lead to the wear-out of plastic discs (washers) which are replaced during the overhaul. Specialists also frequently replace a complete kit of bushings. Worn-out bushings lead to the oil starvation of frictions.

The list of spare parts for this transmission also includes:

- The kit of the overrunning clutch separator (springs and rollers)

- The pressure centrifugal regulator (Governor) is usually rebuilt.

- Solenoid of the torque converter lock-up for А670 introduced in the hydraulic 3-speed for switch-on of an early lock-up.

A404 /470 /670, 30TH/31TH is a family of unique transmissions produced by Chrysler having a solid reserve of transmission components.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Chrysler	PT CRUISER	0	3 SP FWD	L4 2.4L
Chrysler	VOYAGER	1	3 SP FWD	L4 2.4L V6 3.0L
Dodge	CARAVAN/GRAND CARAVAN	95-00	3 SP FWD	L4 2.4L
Dodge	NEON	95-01	3 SP FWD	L4 2.0L
Dodge	SPIRIT	95	3 SP FWD	L4 2.5L V6 3.0L
Plymouth	ACCLAIM	95	3 SP FWD	L4 2.5L V6 3.0L
Plymouth	NEON	95-01	3 SP FWD	L4 2.0L
Plymouth	VOYAGER/GRAND VOYAGER	95-00	3 SP FWD	L4 2.4L

How to repair this transmission (Videos)

Teardown Inspection

Instruction manuals and useful links

Link type	Source	Description
0	www.at-manuals.com	Technical training A413
pdf	www.at-manuals.com	Scheme A413
web	www.at-manuals.com	Solenoid application chart A413

6HP19 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 6-speed automatic gearbox ZF 6HP19 /A (09 ) has been installed on RWD and AWD BMW models, as well as on FWD and AWD Audi models (as 6HP19A). This transmission can be paired with engines with capacity up to 3.5 liters. ZF 6HP19 was constructed jointly with ZF6HP26 as a “light” modification. Aisin’s TR-60S and VW's DSG-6 are considered the main competitors of this ZF unit. VAG is the main user of ZF transmission solutions. In 2006, ZF released 6HP21 and 6HP28 modifications. These two units have the same new Mechatronic unit of the 2nd generation with improved gear shifting mechanism. ZF engineers also improved the valve body, replaced solenoids, replaced some friction elements and almost all steel plates

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/RWD/AWD	420	9	4	Shell M-1375.4

Technical issues and repair guidelines

ZF recommends changing ATF in this transmission no later than after covering 100 thousand kilometers or after 8 years of running under the condition of "careful" driving style. The amount of required ATF for a full change is 9.5 L. This gear shifting unit operates with any good quality fluid such as Dexron VI. It is advisable to make two partial fluid changes in case of contaminated fluid and at the same time to change the filter.

Transmission specialists usually replace solenoids when the car with this transmission reaches high mileages and problems with gear shifting. The torque converter is also rebuilt in the process solenoid replacement.The complete reassembly includes removal of the transmission unit, and order of the repair kit of gaskets and seals. In the process of reassembly, the whole set of friction components is replaced, especially when ATF gets burned. The full kit of bushings is replaced as well.

Typical problems of ZF 6HP19-21

The most common problem for powerful cars equipped with this transmission is the torque converter. Its locking mechanism became regulated and forced from the first gear.The main problem of 6HP19\21 – is the Mechatronic unit. Electronic components are sensitive to temperature drops and falls– too high and too low oil temperatures as well as the presence of metal chips are undesirable factors for this transmission.The main spare part of 6HP valve body became the separator plate of the valve body.

Structural peculiarities of this gear shifting unit (vibrations of torque converter and pump stator, operating with oil shortage...) lead to fast wearing of bushings.The wear of bushings results in pressure losses in corresponding packages and the control unit opens electromagnetic valves of solenoids more and more in order to compensate oil shortages. Common replacement part – the pump seal, and less frequently - output shaft seal. Transmission specialists frequently replace worn pump bearings.

The main problem for the 6HP19 unit in winter time is replacement of the adapter to the block of solenoids (also called as “Sleeve”). It is recommended to replace the “Sleeve" within the framework of the sheduled repair without waiting for its damage. The common spare part in summer time is the adapter to mechatronics. This adapte, included in some repair kits, has a short service life and recommended for change each 2-4 years. With this repair part, it is also advisable to replace sealing tubes of the valve body.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	S4/RS4	04-09	6 SP 4WD	V8 4.2L

How to repair this transmission (Videos)

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Spare parts catog 6HP19
web	www.at-manuals.com	Solenoids manual 6HP19 (09L)
pdf	Sonnax	Valve Body Layout ZF6HP19/26/32 (Gen. 1) With 053 Separator Plate
pdf	Sonnax	Valve Body Layout ZF6HP19, ZF6HP26, ZF6HP32 (Generation 1)
pdf	Sonnax	ZF6HP21/28/34 (Generation 2) Valve Body Layout
pdf	Sonnax	Vacuum test ZF6HP19/26/32 (Gen. 1) with 053 Separator Plate
pdf	Sonnax	Vacuum test ZF6HP19/26/32 (Gen. 1)
pdf	Sonnax	ZF6HP21/28/34 (Generation 2)

6HP26 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

This 6-speed automatic transmission was designed by ZF jointly with BMW. Since 2001 this transmission has been used for all high priced vehicles with rear-wheel drive and engines with the capacity of up to 6 litres. The list of brands using this transmission includes Bentley, Aston Martin and Maserati. Since 2006 this transmission has been used in Ford, Hyundai, Jaguar, Land Rover.The 6HP26A modification found application on FWD Audi and VW models. It has the torque capacity of up to 600Nm.This 1-st 6-speed automatic transmission from ZF triggered the start of production for next generations of this family - 6HP19 -21 intended for engines with lower torque (up to 420 Nm) and 6HP32 – for max torque (up to 750 Nm).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	FWD/RWD/AWD	420	12	6	Shell M-1375.4

6HP26 Specs

The gearbox is controlled by a revolutionary for that time TCM (transmission control module) named the ZF 6HP Mechatronic / Mechatronik. The 6HP26 torque converter boasted an innovative lockup system with a peculiar mechanism, which facilitated lockup in all 6 gears. Multiple gear ratios in the ZF 6HP26 transmission were housed inside a small area, using a conventional planetary gearset and a gear assembly designed by P.Ravigneaux. Power transfer actions are covered by 5 clutch packs. At that, compared to its predecessor, the ZF 5HP, this 6-speed transmission used fewer parts and was lighter

6HP26 Typical problems, technical issues and repair guidelines

Typical problems for this transmission family includes: vibrations which lead to wear of bushings and drum Е resulting in problems with 4-5-6 gears shifting; issues with other speeds caused by wear of solenoids and torque converter lock-up result in problems with the pump and seal leakage, slippage of frictions (slow acceleration) which leads to overheating, burnt oil and necessity for automatic transmission reassembly with the use of repair kits.

6HP26 Mechatronic problems

The mechatronics unit is similar to the one used in 6HP19 and they have the same problems. There are two generations of valve bodies.VFS (Variable Force) solenoids frequently become the source of numerous issues. Intensive operation on cross-section in the environment of contaminated fluid and high temperature leads to premature wear and abnormal operation. Mechatronics in these ZF automatic transmissions are sensitive to static electricity, even when touching contacts with your hands.

6HP26 Mechatronic Seal Issues

Issue: a range of common 6HP26 transmission are frequently due to loss of pressure from the required level caused by the wear or failure of the small seal between the 6HP26 transmission mechatronic controller and the transmission case. If it fails, the following 6HP26 transmission problems will manifest themselves:

Unexpected 6HP26 clutches failure,
Transmission pump malfunction,
Failure of the torque converter clutch.

Solution: replacement and reinstallation of the 6HP26 Mechatronic adapter seal.

6HP26 Pump problems

Worn pump bearing and pump stator are frequently replaced during maintenance services. Problems of both abovementioned parts are related to worn components of torque converters and related vibrations. Typical replacement operation of the first priority is related to the overheating and aging of the rubber: - Separator plate of the valve body, 6HP26/ 6HP19.Overdrive Е package with frictions, steel and thrust discs gets burned first from clutch packs. The same problem is typical for structurally similar 6HP19.The problem in winter time – replacement of the adapter to the solenoid assembly.

6HP26 Torque converter problems

The torque converter is a common problem for powerful vehicles equipped with this transmission. If repair specialists order bushings, then it means the torque converter repair as well.After the overhaul it is required to reset computer settings. This family of ZF6HP transmissions is in great demand in the repair business and at the same time is considered to be as repairable as its predecessor - 5HP19. The service life of this transmission can reach 1 “million” kilometers under the condition of timely and accurate overhaul of the transmission (as well as maintenance).

Excessive wear of the TC clutch in the 6HP26 torque converter due to active lockup triggered even at as low as 1st gear. Subsequently, drivers can experience the following problems:

Delays in engaging the right gear,
Slipping gears,
Unpredictable up/down shifting,
Excessive heating of the transmission,
Unusual noises from the transmission.

Solution: key to remedying the ZF 6HP26 torque converter problems is installation of a new / replacement torque converter unit. Torque converter repair specialist might effectively use certain special tools helpful in the remanufacturing procedure. It is also important to remember to address replacement of the excessively worn transmission fluid and issues with cooling.

6HP26 Solenoid Issues

Issue: different gear ratios are controlled by 7 solenoids and if one of these 6HP26 solenoids becomes damaged or worn out, following problems arise:

Delays in shifts,
Sticking gears,
Refusal to turn a gear,
Slipping gears.

Solution: a serious number of common problems with 6HP26 transmission is due to valve body solenoids failures. The right approach to remedy this is replacement of the faulty 6HP26 solenoid. Solenoid testing equipment is recommended to identify the damaged one.

6HP26 E Clutch failure

Issue: wear out of the 6HP26 clutches, which are key in power transfer from one gear to the next. Friction material used in the clutches is important for grabbing. Improper maintenance or reckless driving will wear them out prematurely. The common 6HP26 clutch failure symptoms are as follows:

Clutch slipping,
Delays in shifts,
Harsh shifts,
Failure of gear engagement,
Excessive heating.

Solution: rebuilding or replacement of the transmission unit corrects this common 6HP26 transmission issue.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A4/A4 CABRIOLET	02-13	6 SP F/4WD	L4 2.0L V6 3.0L V8 4.2L
Audi	A6	04-11	6 SP F/4WD	V6 3.0L V8 4.2L V10 5.0L 5.2L

How to repair this transmission (Videos)

Teardown

Bushing Kit Installation

Bushing Kit Installation Part 2

Valvebody Overhaul

E-Shift Valvebody

ZF 6HP Rebuild

Remove Mechatronic Case Connector

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Transmission breakdown illustration 6HP26
pdf	www.at-manuals.com	Spare parts catalog 6HP26
web	www.at-manuals.com	Pockets 6HP26
pdf	www.at-manuals.com	Scheme 6HP26
web	www.at-manuals.com	Application chart 6HP26
pdf	Sonnax	ZF6HP19, ZF6HP26, ZF6HP32 (Generation 1) Valve Body Layout
pdf	Sonnax	ZF6HP19/26/32 (Gen. 1) With 053 Separator Plate Valve Body Layout
pdf	Sonnax	ZF6HP21/28/34 (Generation 2) Valve Body Layout
pdf	Sonnax	Vacuum test ZF6HP19/26/32 (Gen. 1) with 053 Separator Plate
pdf	Sonnax	Vacuum test ZF6HP19/26/32 (Gen. 1), FORD 6R60/6R75/6R80
pdf	Sonnax	Vacuum test ZF6HP21/28/34 (Generation 2)
web	Sonnax	Solving the 6R80 Transmission Leak Mystery

09D Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The TR60-SN (09D according to VAG) is an innovative 6-speed automatic transmission designed by Aisin and released in 2003 for RWD Porsche Cayenne equipped with a 4-liter engine.

This transmission was designed simultaneously with the first 6-speed automatic transmission for FWD cars - TF60-SN and was tested since 2001 on a 2-liter Altezza

This transmission was supposed to be a leader in the world of luxury brands such as Porsche, Audi, Lexus and become a competitor to the new 6-speed ZF6HP transmission. Audi use 09D for Q7 SUVs with diesel engines from 3 to 4.2 liters.

EAW TR-60SN has been successfully used since 2007 in powerful (over 4.6l) RWD and AWD Lexus and Land Cruiser SUVs. There are several sub-modifications of this transmission for its torque class, differing in planetary gears, quantity of clutches and steel discs, the size of some of the units and parts. It was replaced by the 8-speed transmission TR80-SD.

This transmission was designed by the Aisin to become "invincible", like all of its RWD automatic transmission. But each automaker customized its TCM (transmission computer) in "democratic" fashion, enabling drivers to use its capacities to the fullest extent.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
6	AT	RWD/AWD		12	8	Toyota WS

Technical issues and repair guidelines

The repair kit of gaskets and seals is always ordered with filters for reassembly procedure. It is usually ordered for changing teflon rings which must be changed to save friction components and the pump with solenoids. If the car is used with worn out teflon rings, then the friction elements get burnt and the rubber seals get harder because of the temperature.The overhaul is always accompanied by the replacement of burnt frictions and steel disks for K1, K2, B1 clutches. The reason is usually related to clogged valve body, solenoids, and seals. It is expressed in slippage of clutches under load or delays with shifting of gears.

The most problematic components of 09D:

The main problem of 09D installed in Volkswagen is related to clogging and breakdown of the hydraulic clutch plate with solenoids caused by ATF overheating and burning of the hydraulic clutch friction lining.
The torque converter is usually handed in for repair in order to replace worn-out clutch lock-up.
The wiring of solenoids often causes some malfunction. Older transmissions are provided with external fine filter.
Valve bodies for Tuareg are often handed in for repair.

For these transmissions it is recommended to take measures on improving the transmission cooling system, for example, by installing an additional radiator. It is also advised to check the ATF condition and change it as soon as it gets darker and loses transparency.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	Q7	05-13	6 SP R/4WD	V6 3.0L V8 4.2L
Volkswagen	TOUAREG	02-10	6 SP 4WD	V6 2.7L 3.0L 3.2L 3.6L L5 2.5L V8 4.2L V10 4.9L W12 6.0L

How to repair this transmission (Videos)

Pressure-Test front pump seal

09D SHIFT KIT

AW 6 Speed Solenoid Repair

Instruction manuals and useful links

Link type	Source	Description
pdf	volkspage.net	Self-Study Programme TR60SN 09D
web	sonnax.com	TR-60SN Valve Body Layout
pdf	ukrtrans.biz	TR60SN Technical Service Information
web	www.at-manuals.com	Component application chart TR60SN 09D
web	www.at-manuals.com	Solenoid/clutch application chart TR60SN 09D
web	www.at-manuals.com	Valve Body with solenoids TR60SN 09D
pdf	Sonnax	Valve Body Layout TR-60SN

5HP19 Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 5-speed automatic transmission ZF5HP19 (with ./FL ../FLA modifications) - is considered to be one of the most popular automatic transmissions in the repair industry. Although this transmission was replaced by no less popular ZF6HP26 - 6HP19, this 5-speed unit is still widely used and repaired.

It should be noted that the popularity of this transmission among repair specialists has nothing to do with its quality, on the contrary, this efficient transmission was installed on extremely durable cars. It is the case when good cars get a good transmission. First 5HP19 units were introduced in 1995 on front-wheel and all-wheel drive Audi. These gear shifting solutions were designed on the basis of 4-speed 4HP18 and 5-speed 5HP18 (thus, most of components in these transmissions are identical). The main peculiarity of 5HP19 is higher torque in comparison with 5HP18 and that it can be paired with engines up to 4 litres. The FL version of this transmission was designed for the line-up of FWD models from Audi-Volkswagen. The 5HP19FLА transmission is designed for 4WD cars with V6 engines. The 5HP19 unit found application in rear-driven BMW cars. According to VAG classification, ZF 5HP19 transmission is also known as 01L or 01V (for some vehicles).

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
5	AT	RWD/AWD/FWD	325	9,7	4-5,5	LT -71141

Technical issues and repair guidelines

The repair kit of gaskets and seals for BMW is the most popular kit ordered for this transmission. The kit of frictions is also included in a standard order for this transmission.

The operational resource of this transmission before the first overhaul is significantly higher than standard 120,000 miles, but this parameter heavily depends on operating conditions. This reliable transmission can endure operation under severe conditions and heavy loads, but oil starvation will have a negative impact on its operability.

The torque converter of this transmission is one of the most frequently repaired units. This torque converter is one of the first converters with early introduced ( 3-rd speed) forced lock-up mechanism, which damages the friction lining. The pump cover bushing is one of the most frequently replaced elements.

As for friction discs in the 5HP19 transmission, in most cases repair specialists have to replace discs of the first "С" package near the pump. The replacement of friction components is always accompanied by replacement of sealing rings as the wear-out of these rings leads to burning of friction packages.

The pressure solenoid (EDS-1 EPC) is loaded more in comparison with solenoids, therefore it works out its resource earlier.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	S4	00-02	5 SP 4WD	V6 2.7L

How to repair this transmission (Videos)

ZF 5HP19 transmission assembly

Rebuild Part 1 BMW

Rebuild Part 2 BMW

ZF5HP19 Teardown

Gear Monitoring Codes

Valvebody

valve body additional information

Torque converter

Instruction manuals and useful links

Link type	Source	Description
pdf	www.at-manuals.com	Spare parts catalog 5HP19
pdf	www.at-manuals.com	Repair manual 5HP19
web	Sonnax	ZF5HP19 Solenoid Identification

01N Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

In 1991, the 4-speed automatic transmission (A/T) 01N (097) successfully replaced another popular transmission solution named as 090. It was designed for FWD Audi cars (A4, A6, etc.) equipped with engines from 1.6l to 2.6l. It was also installed on some VW Passats with different longitudinally positioned engines with the capacity up to 1.9 liters.The transmission, manufactured from 1991 to 2004, has three modifications corresponding to their production years: 1991-95; 1996-1998; 1999-04. Thus, these versions have some differences in the design of transmission components.VW have similar modifications of this family: 098/01P – the engine is located transversely in minibuses and MPVs. VW Sharan, VW T2/T4, VW Eurovan, Ford Galaxy; 095/096/01M – the engine is located transversally for VW and SСODA cars.These automatic transmissions differ in housings and differentials.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	280	6	3,8	LT 71141

Technical issues and repair guidelines

The 01N (together with 098/01P and 095/096/01M) - the leader among Audi-VW transmissions in repair frequency. The 01N steadily holds the third place in demand, behind only a younger family U140-240 and the unconditional leader 5HP19(FL).This transmission is very reliable, maintainable, simple, and some problems usually occur only after large mileages.

Often transmission specialists change only the burned-out 3-4 (K3) packs and Forward-Rev together with bearing discs, separate plastic bearings, gaskets, pump and seals. Electric components and the valve body units usually have tha same issues as in the 01M transmission. The torque converter is the main source of faulty operation of the valve body. The sooner the torque converter lock-up lining is replaced, the less is the wear-out of solenoids and the valve body.

The standard order for reassembly of the old 01N transmission includes filter and complete kits: Overhaul kit, Frictions, Pistons.

Ordered Kits:

-Kit of gaskets and seals;

-Kit of friction components, usually ordered with the kit of steel discs;

-Kit of pistons is the same for 01M-N-P, and it is ordered for most major repairs.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A4/A4 CABRIOLET	00-01	4 SP F/4WD	L4 1.8L V6 2.6L 2.8L

Instruction manuals and useful links

Link type	Source	Description
pdf	www.parker.com	TRANSMISSION KIT & COMPONENTS CATALOG

01M Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The legendary 4-speed automatic transmission 01M of Audi-Volswagen own manufacture (preceded by 095 / 096 models) has been produced for 20+ years, from 1995, for all popular FWD VW, Seat and Skoda (as well as Audi А3) vehicles with engines from 1.6l to 2.0l positioned transversally.

The most popular transmission in rebuilding is the 096 transmision. It had been assembled at some Volkswagen factories until 2009, while the 01M has been installed on the Passat series (China) up to the date. The German factories used the the 01N unit on the Passat series with various engines (A4, A6, Cabrio).

The less popular modification 01P (its predecessor is 098) capable of transferring a higher torque was used with up to 2.8l engines in VW Sharan, VW T2/T4, VW Eurovan, Ford Galaxy (micro buses and minivans). In terms of design, this transmission is similar to the 01M and these models have many compatible spare parts.The 097 transmission had been used in Audi 80 and 100 models unil 1995, when it was replaced by not less reliable 01N.

This family of automatic transmissions was the last masterpiece of VW-Audi Group, which tried to stay competitive on the automatic transmission market. The 5-speed ZF 5HP19 released in 1995 smoked the competition, and VAG soon decided to close the production of its automatic transmissions and started using products of Aisin Warner and ZF.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
4	AT	FWD	200	6,5	3,8	LT 71141, 75W90 GL4

Technical issues and repair guidelines

One of the peculiarities of the 01M transmission lies in the transversal positioning of the unit. Therefore, VAG engineers also had to add a differential with a separate lubrication system (i.e. oil for it is tested and replaced separately).Gasket and seal repair kit (Overhaul kit) for the 01M is frequently ordered for the transmission repair. Rebuilding procedures, especially when there is burnt oil, require a full set of the friction components.

The list of 01M vulnerabilities includes the following:

The rubber hardens and poorly endures pressure, especially in winter. Older vehicles and overheated automatic gearboxes have the full set of rubber-coated pistons replaced in them.
The drum 3-4 may become worn out due to breaking of the basket along the axle of the shaft.
The green front drum washer - plastic sliding bearing - melts or becomes brittle due to the temperature and lateral pressure effect.
It is believed that 8-10 years is the average normal lifespan for all 01M-01N electrical components, including sensors. After this term, the resistance of its wiring starts to increase, the channel gets worn out, the characteristics of the valve closure change, and the computer "rejects" them.
The Valve Body requires regular cleaning. For vehicles that covered over 150-200 thousand km this procedure is a “must”. (As well as Torque Converter rebuilding)
ATF contamination comes from the Torque Converter and is a result of the dust flow from friction linings and worn out bearing washer. Contaminated ATF blocks channels and corrodes metal of these channels at some most loaded valves of the Hydraulic unit.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A3	00-06	4 SP F/4WD	L4 1.6L 1.8L 1.9L
Seat	TOLEDO	96-01	4 SP FWD	L4 1.6L 1.8L 2.0L
Volkswagen	CABRIO	95-01	4 SP FWD	L4 2.0L
Volkswagen	GOLF/GTI	95-06	4 SP FWD	L4 1.8L 2.0L 1.9L DIESEL
Volkswagen	JETTA	02-05	4 SP FWD	L4 2.0L 1.9L DIESEL
Volkswagen	PASSAT	95-11	4 SP FWD	L4 1.9L 2.0L V6 2.8L

How to repair this transmission (Videos)

Automatic Transmission Service Group

VW 01M Transmission

Instruction manuals and useful links

Link type	Source	Description
web	Wikipedia	Volkswagen 01M transmission
web	kansascitytdi.com	01M Transmission Removal and Reinstallation
web	kansascitytdi.com	01M Valve Body Removal and Reinstalation
web	kansascitytdi.com	01M or 01P Valve Body Repair
pdf	just-t4s.co.uk	01M, 01N, 01P UNCONTROLLABLE HARSH 1-2 UPSHIFT
web	kansascitytdi.com	01M Filter change
pdf	europeantransmissions.com	01M/01N/01P 1996-2000 OBD-II CODE DEFINITIONS

01J Transmission parts, repair guidelines, problems, manuals

Mon, 15 Dec 2025 00:00:00 -0700

Transmission general data

The 01J CVT transmission ( 0AN Multitronic or VL-300) was produced by Audi collaboratively with the company LuK GmbH & Co in 2002 for popular AWD models А4, А6, А8 with engines from 1.8 up to 3 liters. It transmits up to 310 Nm of torque.

Audi came up with a lot of names for different sub-modifications of this transmission, but all these CVTs versions have basically the same design and internal components and can be repaired with the help of the same repair kits.

Number of gears	Transmission Type	Drive	Torque (Nm)	ATF (full capacity) L	ATF (change) L	ATF type
∞	CVT	FWD	310	7,5	4,5	G 052 180 A2

Technical issues and repair guidelines

The main reason for visiting a repair shop with this durable CVT during the first years of exploitation is the necessity to replace the filter and ATF (G 052 180 A2). About 4.5 liters are required for partial ATF change. Complete ATF change via double partial change - requires 7.5 liters. This CVT is sensitive to the CVT quiality (level and cleanness). It is recommended to perform the ATF change after travelling 40-60 thousand kilometers, but the older CVT unit, the sooner the replacement should be performed. Opaque ATF is the sign that it is a high time to visit the nearest repair shop.

The structure of CVT 01J is especially sensitive to ATF contamination. The usage of contaminated ATF and clogged filter leads to the premature damage of the transmission components.The common order for the overhaul of this CVT includes the repair kit of gaskets and seals. Another typical spare part for repair of this transmission is an ejection pump.

The ejection pump is made of plastic and operates on the principle of an "atomizer". As in all atomizers, this system is sensitive to cleanness and temperature of the ATF. It gets clogged very quickly and channels wear out. Usage of contaminated and hot ATF leads to low efficiency and such oil should be changed together with other spare parts. Problems with this pump result in some issues with friction elements.

Vulnerabilities of 01J:

The structural design of this CVT exploits a pulling mechanism. Such mechanism exhausts its performance potential quite early, because of stretching loads and frictions, therefore it is changed during each CVT overhaul (after covering 100 thousand kilometers). Usually the pulling plates are replaced together with the pulling mechanism.
The CVT design excludes the possibility of cars towing, otherwise it may lead to lethal consequences for CVT cones and as a result serious problems for transmission itself. Cones are the primary resource of the CVT unit
The control unit of CVT Multitronik VL-300 (with the resource no higher than 100 thousand kilometers) is a common soft spot of electrics for CVTs and 6-speed gearboxes of the first generations.
Another serious problem (less frequently met) is the differential.
It is strongly recommended to pay much attention to the differential condition during the overhaul. If there is a problem with the differential then the gearbox can be considered “dead”. The replacement of 01J differential is a practically impossible task.

Generally, this sophisticated and accurately adjusted gearbox operates quite well in new cars, but after 150-200 thousand kilometers the usage of this transmission reminds a “Russian roulette”.

Which cars run with this gearbox?

Brand	Model	Year	Type	Engine
Audi	A4/A4 CABRIOLET	00-13	CVT F/4WD	L4 1.8L 1.9L 2.0L V6 2.4L 2.5L 2.7L 3.0L 3.2L
Audi	A5/A5 CABRIOLET/A5 SPORTBACK	06-13	CVT F/4WD	L4 1.8L 2.0L V6 2.7L 3.0L 3.2L
Audi	A6	00-13	CVT F/4WD	L4 1.8L 1.9L 2.0L V6 2.4L 2.5L 2.7L 2.8L 3.0L 3.2L
Audi	A7	10-13	CVT F/4WD	V6 2.5L 2.8L V6 3.0L
Audi	A8	03-10	CVT F/4WD	V6 2.8L 3.0L 3.2L

How to repair this transmission (Videos)

Audi cvt 01J atsg

How to repair cvt step by step

Instruction manuals and useful links

Link type	Source	Description
pdf	www.volkspage.net	Design and Function Self-Study Programme 228
pdf	www.at-manuals.com	Variable Automatic Transmission multitronic 01J
pdf	Sonnax	Valve Body Layout 01J
web	Sonnax	VW/Audi 01J/01T Valve Body Identification Guide

Twitches in automatic transmission? What is the problem?

Mon, 15 May 2023 00:00:00 -0700

Why are there twitches with your automatic transmission?

Automatic transmission is currently installed on a large number of cars, but drivers are divided in their opinions about it. Some agree that it is extremely convenient, others say that it is more trouble than good. In particular, the claims relate to very expensive repair rates, because certainly, just as any other engineered element, it sometimes fails.

Of course, any failure will make itself visible by the corresponding manifestations, so the driver will be able to start the process, carry out required repairs without going to extremes, waiting until the need for complete replacement of parts arises.

Of all the problems, drivers are more likely to complain that when changing gears, the machine starts to twitch. This is the most important sign that something is wrong with this mechanism. It is very important not to keep on going with this problem and fix it as quickly as possible, because it is not known at what point the situation may worsen.

There are several reasons why the automatic transmission starts to twitch at all:

· Problems in operation or complete failure of the torque converter.

· Some parts of the mechanism are severely or completely worn out and need to be replaced.

· All available adjustments are detuned.

· Poor operation and uneven movement of the cable (its deterioration).

· Problems with the electrical part of the box (restricted current flow, short circuits within the mechanism, etc.)

· The control unit is not working properly.

· Seriously worn-out condition of the clutches.

It is worth noting that these troubles can affect any gearbox, which in the end threatens with its complete failure.

If the twitches are felt only when you decrease or increase speed, then the range of reasons can be somewhat narrowed:

• There is too little or too much transmission fluid in the mechanism.

• The transmission fluid itself was poorly selected or is no longer suitable for use.

• Cushions of the transmission are in bad condition.

• There are problems in the chassis of the car (most likely clearances).

• The car (engine) is poorly warmed up, but in this case the problem should disappear after a good warm-up.

Basically, the problem is determined after diagnostics of both the entire car and the gearbox in particular. This may also be indicated by uneven or incorrect pressure in the hydraulic system or unstable engine operation at any speed.

The solution to the problem depends, in fact, on the type of the problem. If the matter is due to the liquid type, it is most often replaced (it is important that it is suitable for a specific automatic gearbox type) and then you shall strictly control the liquid level. If the reason is in worn-out parts, then they should definitely be replaced with new ones and simply do not try to repair them or save on the purchase of the replacement parts.

By the way, it is better to use the transmission fluid that is recommended by the manufacturers of a particular car. Moreover, it is important to change it exactly at a certain time (along with the filters). This will extend the service life of the automatic transmission itself.

We advise not to target saving when buying elements of the gearbox, since bad purchase will cost you complete gearbox replacement later, and this will be much more pricy (besides, you might require a lot of time and effort looking to find the necessary parts).

Transmission Solenoid and Test Methods

Sat, 13 May 2023 14:00:00 -0700

Transmission Solenoid Test Methods

The variety and shape of solenoids used in modern transmissions changes with each new model. On any rebuild, solenoids are a suspect part and should either be tested and verified for proper operation or replaced. Some shops opt to just replace all the solenoids on the valve body. On some models that makes sense as the replacement solenoids are fairly cost effective. For other models, the cost of either OEM or aftermarket replacement solenoids do make it worthwhile to test and only replace the ones that are worn or faulty.

Figure 1: Hydra-Test HT Sol Solenoid Test Machine

When you test a solenoid, a hydraulic solenoid testing machine with specific adapters for each solenoid is by far the best and most accurate way to test. The Hydra-Test HT Sol has become the industry standard for solenoid testing with a range of adapters that can fit most any solenoid.

The machine comes with full documentation and can guide you through the testing process. For the purpose of this article, I am not going to go into detail on the HT Sol. I want to focus on the basic solenoid and testing terminology such as how you can identify solenoid types, and what kinds of a test methods you would use to accurately test the different solenoids. A good understanding of this will give you a good understanding on what you are trying to achieve when you are testing.

Let us start with some characteristics and terminology used when talking about solenoids.

Solenoid Resistance:

One of the key measurements of a solenoid is to use a multimeter to measure the resistance of the coil. This is a quick and easy check where you can find if you have a short circuit, open circuit, or the possibility of a partially shorted solenoid coil. An important thing to remember is that when you measure the resistance, you are measuring the resistance of the coil, which is a very, very long piece of wire. Unlike a true resistor, where the resistance stays constant over a wide temperature range, the resistance of a solenoid coil will measurably change over temperature (for example between room temperature and 200F).

Normally Open or Normally Closed:

This refers to the hydraulic state of the solenoid when it is off with no electricity applied. A normally open solenoid would allow oil to flow from the inlet to the outlet. A normally closed solenoid would block oil between the input and output. Applying power to the solenoid will switch it to the opposite state. Sometimes these solenoids can be almost identical and will fit in the same hole on a valve body. You can imagine the shift issues that can be caused if this happens so be sure to double check.

Electrical Solenoid Activation:

This refers to how the solenoid is electrically driven when it is energized. The simplest method is to energize it with ignition voltage and allow it to draw full current. The next most common method is to use pulse width modulation (PWM). PWM is pulsing the solenoid on and off many times a second, and the amount of on time vs. the amount of off time is varied to change the amount of average current the solenoid will draw. There is one other method that called peak and hold that I will detail in another article. This method is used by Chrysler and it is similar to PWM but allows the ability to regulate current slightly differently on low resistance solenoids.

Generally, solenoids can be categorized into two types. The first is an on/off where the solenoid either allows full pressure at the outlet or blocks pressure to the outlet. The second is a pressure regulating solenoid where the output pressure from the solenoid is regulated to a desired valve by the varying the current draw of the solenoid.

Figure 2: PWM Definition

On/Off Solenoids:

On/off solenoids are generally smaller in construction.
On/off solenoids have higher resistance and if you measure the resistance it is usually greater than 10 ohms.
Continuous current through these solenoids is around the 0.4-0.7 A and they are designed to handle that amount of current indefinitely.
These solenoids were the primary used as shift and torque converter clutch solenoids in early applications. As transmissions and shift strategies have become more complex, they have been replaced by regulating solenoids.
These solenoids cannot regulate pressure and will apply full pressure to the outlet.

Figure 3: ZF Shift Solenoid | Figure 4: Honda Shift Solenoid

Testing On/Off Solenoids:

Testing of on/off solenoids is straightforward. Pressure should be applied to the inlet and if it is normally closed you should not see pressure at the outlet. Once energized with ignition voltage, you should see pressure at the outlet. For a normally open solenoid, the opposite is true. Pressure applied at the inlet should be seen at the outlet and when it is energized with ignition voltage there should be no pressure at the outlet.

One of the most important aspects of testing an on off solenoid is that there is no leakage through the solenoid when it is in the closed condition. While the solenoid may appear off, wear or cracks internally could allow a small amount of fluid to leak past. If you see leakage, the solenoid should not be reused.

Regulating Solenoids:

These are larger in constructing and incorporate and internal regulating valve.
These have various names such Electronic Pressure Control (EPC), Linear Solenoids, or Trim Solenoids.
These have a lower resistance and if you measure resistance, it is generally less than 10 ohms.
Continuous current through these solenoids is varied and can range from 0 to just over 1 amp.
These solenoids are the most common type used in transmissions today and allow for the smooth application of clutch to clutch shifting as well as the smooth control of the torque converter clutch.

Figure 5: Asian Warner Linear Solenoid | Figure 6: Allison Trim Solenoid | Figure 7: EPC Solenoid

Testing Regulating Solenoids:

Testing of regulating solenoids is a bit more complex. Pressure is applied to the inlet and outlet pressure should be observed as current is varied to the solenoid. Pressure should either increase or decrease with current depending upon if the solenoid is a normally open or a normally closed. These solenoids will have a maximum outlet pressure and applying excessive inlet pressure is not needed and could yield incorrect test results if the solenoid is over pressurized.

The most important aspect when testing a regulating solenoid is that pressure changes smoothly as current is varied and that the outlet pressure is always the same at a given current. Solenoids that are worn will show a difference in outlet pressure at a given current. These solenoids can also stick and have a dead spot where even though the current changes, the outlet pressure remains the same. Lastly if the outlet pressure is not steady and fluctuates rapidly at a given current, then this is an indication that the solenoid may be having trouble regulating.

The best way to visually see how a regulating solenoid is performing is to sweep the current and graph this against pressure. A sweep from zero to max (1-1.3 amps) and back to zero should reveal a smooth graph where pressure changes as the current increases and decreases. One key item to note is that the pressure at a given current value is nearly the same as you increase current and then decrease current to come back to the same current valve. This difference is called hysteresis. There will be some difference of this pressure value (or hysteresis), but it should be minimal. As regulating solenoids wear the hysteresis increases noticeably.

One last item that is important on regulating solenoids is that certain ones have an adjustment screw that allows adjustment of the pressure vs. current relationship, i.e., you will measure more or less pressure for all current values as you adjust the screw in or out. This adjustment screw should not be set to an arbitrary setting, but rather set to match a known “calibrated” solenoid. The TCM in the vehicle has an expectation of what this pressure vs. current relationship should be and you can easily adjust this outside it expected range. When adjusted outside the expected range the solenoid technically functions properly, but the pressure vs. current is now outside of what the TCM expects and this can cause shifting problems and fault codes.

Pressure regulating solenoids that do not have smooth pressure vs. current curves, fluctuate output pressure at a steady current, have large hysteresis values as you sweep them, or cannot be adjusted to match a known good pressure vs. current relationship indicate excessive wear or a faulty solenoid and should not be reused.

Figure 8: Solenoid Pressure and Current Graph from HT Sol

Evolution of Gear Shifting Mechanisms

Fri, 12 May 2023 14:00:00 -0700

Evolution of Gear Shifting Mechanisms

For the first motor-car designs, it was enough to have a single fixed ratio for driving around. But with the rapid march of technologies, it became obvious that developing cars capable of both rapid speed ups and remarkable max speed rates would need some engineering trick of changing the speed relations – the drive ratios – to match the conditions of the moment. Nowadays, there is still no ideal solutions on how to transmit torque from the engine to the drive wheels — actually, there’s not even a universal agreement on the best location for the switching mechanism that controls the ratio changes.

More and more automakers equip their new models with paddle shifting systems – a shifting technology that came from the racing world. But the evolutionary path from the 1-st gear shifting mechanisms to modern paddles shifters is not about a constant onward progress, but rather like a rollercoaster with many ups and downs. The gear shifting mechanism was relocated from the floor to the steering column and the dashboard and then back to the floor many times, and each time reasons for gear shifter repositioning were caused by different trends or the appearance of new technologies.

While some early car models could function with more than one gear ratio, they could not be shifted while running. Everything changed when Louis-René Panhard and Emile Levassor, created a sliding-gear transmission — and a shifting mechanism — for their 1895 Panhard-Levassor.

1895 Panhard-Levassor

By 1904 almost all car manufacturers had started using sliding-gear solutions. Ratios were changed with a long gear lever sticking out of the car’s floor.

For proper gear shifting, the driver certainly needed some specific skills and experience to match the RPM rate and the selected speed. It was quite a challenging task for inexperienced drivers, but it worked, however, this process was often accompanied with substantial grinding of gear teeth. In later years, engineers developed mechanical synchronizers that made the process of ratio changes much easier. The floor-positioning of the lever still prevailed in automotive designs for more than four decades.

However, at that time, this kind of the lever positioning was quite uncomfortable for a passenger in the center of the front seat, therefore in the late 1930s car makers came up with the idea to relocate the shifting mechanism to the steering column. American cars of that time were quite spacious with a front bench seat designed for 3 passengers, so the column shifter seemed like a reasonable solution.

’39 Plymouth column shifter

A column shifter firstly appeared on the American car in 1938, and stayed on the market as a standard shifter option for 4 decades. One of the first column shifters found application on the 1939 Plymouth. Subsequently, this technology was integrated in Chevrolet and Ford models. Eventually, column shifters, also known as “three on the tree”, were considered as an industry standard. But the column shifter reached its prime in the 1940s when automatic cars started conquering the automotive market, and remained in high demand for more than two decades.

3-speed column shifter in a 1951 Ford

By the 1960s, the column shifting technology was on its way to falling out of favor. This gradual change was motivated by 2 main factors — a closer attention to higher performance capacity and the necessity to optimize passenger-cabin designs.

Since column shifters were not easy to operate and unsuitable for racing, the car manufacturers cut holes in sedan floors and installed shifting levers on gearboxes. Pontiac, for instance, provided a special-order 4-speed manual unit with an aftermarket floor shifter, designed by Hurst, in 1961. This measure helped to significantly speed up the process of gear shifting, and “four on the floor” became indispensable for powertrain designs of performance-oriented vehicles.

Interior of the 1966 Pontiac GTO with a four on the floor Hurst shifter

Performance capacity of new models became the main selling point in Detroit, the center of the automotive industry in the US. Evolutionary changes in automotive interior design made bucket seats and center consoles quite popular, so the bench seat was no longer a problem for mounting a floor shifter. By the mid-1980s, column shifters had almost disappeared from road cars sold in the US. However, this system can still be found widely on North American-market.

With the advent of the new millennium, trends in the gear lever positioning changed again. Some, like the shifters in the Fiat 500 and Honda CR-V were located on an extension of the lower dash. At the same time, some Chrysler and Honda minivans were developed with shifting mechanisms mounted well up on the dashboard.

Dashboard gear lever of the ’11 Honda Odyssey

The appearance of “by-wire” technologies, based on electronics rather than on mechanical linkages, motivated some car manufacturers to consider the steering wheel or steering column as more comfortable installation place for gearshift actuators. But experts and common auto enthusiasts still have no common view on this aspect of the automotive design.

Fluid Foaming (bubbles) in Automatic Transmissions: Causes and Possible Solutions of Foamy ATF

Thu, 11 May 2023 14:00:00 -0700

Fluid Foaming (bubbles) in Automatic Transmissions: Causes and Possible Solutions of foamy ATF

It is well-known that fluids (ATFs) in automatic transmissions serve not only as a lubricant, but also perform a wide range of other tasks. First of all, ATF is a working medium that controls the transmission operation in the valve body unit and transmits torque in the torque converter. ATF also helps to cool the transmission unit during active transmission operation.

During regular maintenance services, drivers of cars equipped with automatic transmissions sometimes can notice numerous bubbles on a dipstick when checking a transmission fluid level/condition. As a rule, this symptom indicates certain faults in the transmission operation. In most cases, transmission fluid foaming is caused by abnormal ATF levels. In this article we will consider the main causes of these problems, its negative consequences, and possible solutions. You can use our tool to check which type of transmission oil is used in your car and how much of it you will require. If you need a transmission mechanic in your area use this transmission shops map to find closest and reliable transmission service.

If transmission oil (ATF) is normal colour

Symptom	Possible cause	Solution
Bubbles on dipstic, ATF is clean, transmission is slipping or engaging slowly	Insufficient ATF level, the oil pump also intakes the fluid with air	Adjust the fluid level
	Depressurization of the oil passage, leakages of ATF through seals and gaskets	Inspect the transmission unit for ATF leaks, at a local transmission shop

Symptom	Possible cause	Solution
Bubbles on dipstick, but ATF is clean, transmission engages smoothly	Result of mixing different transmission fluids	Do transmisison flushing, at a local transmission shop
	Use of improper fluid type	Do transmisison flushing, at a transmission mechanic
	Use of “old” ATF	Check fluid type, transmission flushing is recomended
	Overflow of the transmisison fluid level	Remove excessive oil off

Check out our transmission shops map to find closest and reliable transmission specialist in your location.

You can use our tool to check which type of transmission oil is used in your car and how much of it you will require.

If oil (ATF) is strange colour (light brown or dark brown)

Symptom	Possible cause	Solution
ATF smells like burned and is brown colour	Transmission is damaged. Due to overheating, and ATF is "cooked". Transmission might have worn out friction discs.	Visit your transmission mechanic
	Aggressive driving style	Check safe driving tips, consult a local transmission shop
	Contamination or failure of the automatic transmission filter	Check filter
	Use in hot weather with stop-and-start driving	Check safe driving tips, consult a local transmission shop

Symptom	Possible cause	Solution
The fluid has a milky brown appearance	It indicates coolant contamination. There is probably a leak in the ATF oil cooler inside the radiator that is allowing coolant to mix with the ATF.	Visit your transmission mechanic
	Engine fluid used instead of ATF	Do transmisison flushing, at a local transmission shop

Check out our transmission shops map to find closest and reliable transmission specialist in your location.

You can use our tool to check which type of transmission oil is used in your car and how much of it you will require.

Causes of ATF foaming

In most cases, bubbles on transmission dip stick caused by insufficient ATF level or its overflow and you might need to contact your local transmission mechanic. If the fluid is above the norm, the foam is formed when moving elements inside the transmission unit “grab” the fluid in the pan and make ATF foamy. If the fluid level drops, the oil pump also intakes the fluid with air.Depressurization of the oil passage, leakages of ATF through seals and gaskets can lead to the fluid foaming, too. In some cases, ATF becomes foamy because of severe contamination or failure of the automatic transmission filter.

That’s how foamed ATF looks like

The foam can also appear as a result of mixing different transmission fluids, i.e. foaming is the result of a chemical reaction that causes the loss of fluid properties. The thing is that compositions of modern ATFs include a great number of chemical additives, which ensure proper operation of transmission units. As different transmission fluids include different sets of additives, they often turn out to be incompatible.

For this reason, it is prohibited to mix mineral and synthetic transmission fluids. Disregarding this rule can lead to fallout of precipitation that pollutes operating surfaces, clogs valves, channels, and other components. One more reason for ATF foaming can be the use of “old” ATF. Manufacturers recommend changing transmission fluid every 60,000 kilometers. Aggressive driving style, driving in hot weather with stop-and-start driving can reduce the service interval to 30-50, 000 kilometers without waiting until ATF starts foaming and blacken.

Negative consequences of ATF foaming

It should be noted that if you see large and rare air bubbles on the dipstick during ATF check after intensive driving with high RPM rates, this does not mean that the fluid is foaming. But when there are many evenly spaced bubbles on the dipstick, it is a dangerous symptom that requires a detailed diagnostics.

The process of ATF foaming can be quite harmful for any automatic transmission. The level of transmission fluid and its density are crucial for proper operation of the automatic transmission unit. The appearance of foam, in turn, leads to negative changes in ATF density. As a result, the foamed fluid becomes compressible and cannot create the necessary pressure on friction packages. This leads to oil starvation, slippages of clutches, etc. With ATF foaming, wear products quickly contaminate the oil and hydraulic system, damage valve body channels, destroy valves, etc. Moreover, it should be remembered that automatic transmissions are extremely sensitive to overheating. The appearance of foam in ATF leads to significant reduction in heat removal capacity, thereby increasing the risk of the transmission unit overheating.

Possible solutions and recommendations

At the initial stage, the main symptoms of ATF foaming are kicks and jolts when driving and shifting from P and D or R. Moreover, automatics can also jerk when braking. In any case, if the transmission starts jolting, then it is time to check the transmission fluid. As has been mentioned before, the main reason for ATF foaming is the incorrect fluid level. Ii it is the case, then it is necessary to adjust the fluid level. (Note: the fluid level should be measured after a proper warm-up of the transmission unit.)

ATF levels

If there is a fluid overflow (when the fluid level is higher than the HOT mark), the excessive fluid must be removed. In case of the fluid overflow, the foaming will not appear immediately after the engine start, but after driving under loads and at high RPMs. The ATF removal can be done with a special fluid syringe and a thing tube.

Learn how to check ATF level accurately

In case of a low ATF level, it is necessary to inspect the transmission unit for ATF leaks (pan, cooling pipes, half-axles installation locations). If there are no visible leaks, then it will be enough to add the missing amount of ATF. At the same time, it is necessary to use the same ATF that has already been used in the transmission unit.

As has been mentioned above, there are several reasons for appearance of foam in ATF. If the car owner notices bubbles on the dipstick, then it is necessary to check the ATF level as well as the general condition of the fluid (color, smell, transparency, viscosity). If there is visible ATF foaming, then it is recommended to stop using the vehicle and tackle the problem without any delays, since driving with foamed ATF can lead to the transmission failure and consequent costly repair of the unit.

How to test a trasmission solenoid?

Thu, 11 May 2023 00:00:00 -0700

How are we testing solenoid?

Here are some common processes used regardless if you are a shop rebuilding a transmission on the bench or are a large reman with assembly lines for high volume production of units. In either case, there is a process of disassembly and determining what parts are good and can be reused, and which ones are bad and must be replaced. Many hard parts that can simply be inspected for wear, cracks, or other damage and determined very quickly if they are useable or not. Many soft parts are automatically replaced as they are not reusable. Between these two types of parts are the ones that require some level of testing to determine if they can be reused or if they need to be replaced. Solenoids are a prime example of such a part since a hydraulic test is required to determine if they are still functioning properly.

When we talk about testing, we not only need to understand why we are testing it, but more importantly, the how do we test it . The “why” is fairly straight forward, as we want to determine if it is still functioning properly and that we can reuse it. The how to test it might not be as clear, and there are multiple methods of how to test, and sometimes opinions on how to test that are not always accurate. The basis of testing involves giving the unit under test some type of a stimulus and measuring the response. Then we examine the response and see if it is within an acceptable range or not to determine if it passes or fails. The proper stimulus and what the acceptable range are is things might get tricky.

So how do we test a solenoid? The obvious answer might be to apply a hydraulic pressure, apply an electrical current, and observe the output pressure. In the case of a variable pressure solenoid, different current points should produce different output pressures and these pressure points should either increase or decrease with current depending upon what type of solenoid it is, right? Well, that answer is partially correct.

I was on site with a customer once and we were testing a Ford 5R55E EPC solenoid. This solenoid is a good basic example of a pressure control solenoid and it is easy to see how as we increase current; the pressure should drop. The controller we had was able to vary the current to the solenoid in steps and you would set it to a value and then check on a pressure gauge the output pressure of the solenoid. I started with it off, then set it at 0.3 amps, then 0.7 amps, then 1.0 amps. The pressure decreased each time. I came back to 0.7, then 0.3, and finally back to 0, and the pressure increased with each test point. At each test point I stopped for about 20 seconds so we could check and read the pressure and discuss. The pressure readings matched what we expected. So, we concluded that this solenoid was fine, operating properly, and ready to be put onto the valve body, right? Wrong!

Increasing Current Steps		Decreasing Current Steps
Solenoid Current	Output Pressure	Solenoid Current	Output Pressure
0.0	90 PSI	1.0	5 PSI
0.3	80 PSI	0.7	32 PSI
0.7	30 PSI	0.3	81 PSI
1.0	5 PSI	0.0	90 PSI

This same machine also had an option where we could increment these current steps over time to “ramp” the current to the solenoid from 0 to a maximum and back to zero. It would then graph the response on the computer screen so we could get a clearer picture of what the solenoid response was. We set the max current to 1.0 amp and our total time for the ramp up and down to about 20 seconds and ran the test. When we did this, we saw a vastly different picture. The solenoid would drop pressure as expected as current increased, however as the current decreased, the solenoid would stick for about 5 seconds at minimum pressure and then snap to about half pressure as we continued decreasing current. This repeated each time we cycled the solenoid as we ran it over and over again. From the graph it was obvious we had a problem, which we could only see as we continually increased or decreased the current, rather than just holding it steady at certain current points. Today, this is easy to see on solenoids machines such as the Hydra-Test HT Sol as this test and graphical method is the basis for how their machine is designed to test. At the time I was working with this customer, this method was more or less only done at large remanufacturers.

But as you can see, this gets to the very root of the how do we test it issue. We also need to understand why one method indicated that everything was fine and the solenoid was working properly, while the other clearly showed us a problem that would cause drivability issues, would give fault codes, and possibly damage to the transmission under certain conditions as our line pressure would be much lower than expected in the unit.

Let us think about how this solenoid functions in the vehicle during normal operation. We want to test in the same way and try to mimic the real-world operating conditions as closely as possible. If we think about an EPC solenoid, especially one that is controlling overall line pressure, how does it operate as the vehicle as it goes down the road? Does it sit at a constant current or is the current constantly varying as the driver changes throttle position, if we are shifting gears, or if we apply the brakes? If you answered that it is constantly varying, you are correct. There may be times when it will be constant (say a long stretch of highway where you keeping a constant speed and throttle), but each time we change an input, it ramps the current up or down over time, just like when we ramped the current and observed it on the graph. If we only look at a few points where the current is constant, we completely miss the bigger picture and the solenoid momentarily sticking before it snaps into place due to wear, internal contamination, or damage.

There are two takeaways from this. The first is that a tool (in this case a solenoid test machine with a variable current and graphing capability) is only as good as the operator and how they are using it. It is important to think about and understand how you are testing. The second takeaway relates to testing equipment. If you have a good handle on how to test you can also verify that the equipment you are purchasing has the features and the ability to test properly. Is the ability to ramp solenoid current and see a resultant graph a standard feature like on the HT-Sol or not? Proper testing yields good results and will save you both time and money, as well as the frustration of chasing a bad part that tested “good” because of incomplete testing.

Transmission Control Modules For Hot Rods

Wed, 10 May 2023 14:00:00 -0700

Transmission Control Modules for Hot Rods

If you are used to keeping everything under control, including the gear shifting process in your classic car, you should certainly consider using an advanced electronic transmission in your motorcar. If you make up your mind to give it a try, you will need an additional transmission module/controller to move the performance capacity of your car to a new level.

Designs of traditional mechanically-operated gearboxes (Powerglide, GM TH350/400, Ford C4/C6, and Torqueflite) included a set of vacuum modulators and RPM governors to keep track of shift points. It can be said that these are crudely made units and in many cases WOT shift points can be rather inaccurate. To get the precise WOT shift point, the driver has to perform upshifting or downshifting manually.

Ford C6 transmission

TH350 transmission

Older mechanically-operated gearboxes have to be partially disassembled for installation of shift improving kits intended for modification of the hydraulic circuits and line pressure increase. With more advanced electronically-operated gear shifting solutions, line pressure can be optimized with the help of the controller to adjust shifting firmness in accordance with the user's liking. It should be noted that these controllers cannot be considered as some kind of a cure-all solution for a weak gearbox, but when we are talking about a properly-operating electrified transmission unit, controllers can become a helpful tool in achieving a new level of the driving experience. Some of these solutions offer dyno mode which rapidly engages 3-rd gear and prevents any downshifting. Most systems also will block the TC clutch to exclude any possibility of the converter slippages.

To examine the most interesting solutions in the field of control modules, we will take a look at products currently offered by all the major brands in this segment of the automotive market.

Taking into account that all TCMs are responsible for the same set of operations, the selection process then comes down to examining and comparing of the main characteristics of specific models that may play an important role on the road. Simplicity in design is obviously an asset with its own advantages. For instance, PCS's Simple Shift utilizes dials instead of digital inputs which may be liked by users who prefer analog inputs.

Others may be lured by more compact design. Among the smaller solutions, we can mention the MSD's Atomic TCM that fulfills all the required functions and utilizes an easily-operated handheld device. MSD and the FiTech's Go Shift are also considered as budget-friendly version of the TCM.

Newer TCM solutions may be more appealing in several aspects. The latest designs frequently come with offer improved operating characteristics after eliminating drawbacks of detected in previous versions. One such solution is TCI's new TCU 2.0 system. This controller is not only packed with a range of helpful diagnostic indicators, but also has an upgraded software notable for its robustness.

It is also necessary to mention Edelbrock's autonomous controller, which is operated controlled by means of a wireless android tablet.

When it comes to reliability and durability, experts often recommend considering the HGM Electronics Compu-Shift. Moreover, it is worth mentioning that recently this technology has seen a lot of improvements. HGM engineers have redesigned its original controller by placing the electronics in a more space-saving package that is now named the HGM Sport. Moreover, they also managed to reduce the total cost of the unit thanks to the use of Bluetooth technology that allows you to install a free program on your smartphone or tablet, which will serve as a hand-held screen. Thus, you will be able to monitor a current state of the system and to introduce changes to its settings. It frees you from expenditures on a separate monitor, thereby reducing the cost of the whole system.

Learn more about HGM controllers

A large part of these TCMs will operate on a carbureted engine once a TPS sensor is attached to the carburetor. HGM offers a great conversion kit named the Acculink that helps to install a standard three-pin GM sensor on a variety of carburetors. Holley also offers a conversion kit, but it is intended for 4160/4150 carburetors that come with an electrical throttle.

It is also possible that some owners of performance-oriented cars may want to combine EFI system with an electronically-operated gearbox. FiTech, for instance, integrates controllers into particular EFI systems. Alternatively, customers may consider an EFI system to run the engine with a separate mechanism for the gearbox. We are talking about the systems that interact with the separate controllers via a CAN bus protocol. This communication protocol helps digital systems to rapidly transmit relevant operating parameters.

Holley has achieved similar results with its Terminator-X Max EFI solution. The Terminator-X Max is a budget-friendly multi-point EFI controller for LS engines that is also capable of controlling 4L60E/4L80E transmissions. As Edelbrock has recently released its controller and it wouldn’t be a surprise if at certain point the company will come up with the idea to combine its EFI and TCM into 1 package.

In terms of system options, we should pay attention to the MicroSquirt solution. Combined with the MegaSquirt EFI, this unit has a special shift retard feature that allows retarding ignition timing to ensure power reduction during the gear shifting process.

If you want to equip your car with an advanced 8- or 10-speed automatics, you have fewer options currently available on the market. These sophisticated gearboxes are much more complicated in terms of control, thus there are only two aftermarket TCMs intended for the latest automatics. The 1-st solution called the Quick 6 (operates with different versions of the 6R80) is provided by US Shift. The second is a PCS unit dubbed the TCM2650 that is designed for the GM 6L80E family.

All in all, it can certainly be said that transmission controllers will find popularity among speed fans who want to realize the full potential of transmissions installed in their performance-oriented cars.

Carjackers Fail to Steal a Manual Car Because They Do not Know How to Shift It

Wed, 10 May 2023 14:00:00 -0700

Carjackers Fail to Steal a Manual Car Because They Do not Know How to Shift It

Despite the fact that today cars equipped with manual transmissions become obsolete and get replaced with more advanced automatic models, it still can be useful to know how to drive a stick shift, especially if you plan to steal a manually shifting car. And a recent story from Canada proves this point.

According to the news report, the story took place in Toronto in late November, when two teenagers tried to steal a car from a man, preliminarily threatening him with a gun to get his keys and drive away. Everything was going according to plan until carjackers got inside the car.

Check out the world's FIRST manual Ferrari 430 Scuderia in action

But Art Bartosik, the head of EAG, has recently announced that his team plans to embark on the manual swap for the Mercedes-AMG GT. The factory-made Mercedes-AMG GT comes with a seven-speed DCT transmission only. Since Mercedes never provided the manual option for this model, the EAG team sees a great potential in this project. Actually, this swap task is simplified by the fact that there's another car model on the market, namely the 2020 Aston Martin Vantage AMR, with the same engine as the GT that is sold with a manual transmission option.

Mercedes-AMG GT

The Vantage AMR comes with the 7-speed manual gearbox provided by Graziano. Thus it is quite feasible to utilize this 7-speed unit in the AMG GT model as this transmission will perfectly fit the engine.

Aston Martin Vantage AMR

However, it can hardly be said that this transmission swap will be a piece of cake for the EAG team. According to Mr. Bartosik, the availability of some ready-made shift linkages simplifies the task, but still they will need to utilize custom components and to implement some changes to the drive shaft, console, pedals, wiring, and software. The team of professionals from EAG has enough experience and the necessary skills and know-hows to get the job done.

It is not a secret that spare parts for Aston Martin are quite pricy so it will certainly affect the final price of the AMG GT swap. It is known that the price for the Graziano-made transmission unit costs and after adding necessary elements and labor, the final swap price will reach approximately $55,000. This project is still at its early stage but the company is ready to take orders to see how many customers would be interested.

Volkswagen Group Components Develops Gearbox for All its MEB-based EVs

Thu, 27 Feb 2020 13:00:00 -0700

Volkswagen Group Components develops gearbox for all its MEB-based EVs

VW Group Components has announced that it has designed a transmission system for all the electric vehicles based on the MEB platform. According to the manufacturer, the new product is notable for its compactness and its operating versatility – i.e. it can handle different situations on the road with a single gear. To optimize the design of this gear shifting unit, VW engineers utilized a 2-stage construction with 2 small cogs instead of one larger component.

All drive solutions for e-cars based on the MEB – including the 1-speed gearbox – are made at the production facility in Kassel. Other crucial parts are produced at the three other facilities of the company. Thanks to this unique transmission system, the e-drive motor in the ID.3, VW’s first mass-produced e-car, generates the max torque of 310 Nm constantly over a wide range of speeds. The e-car can pick up a max speed of 160 km/h at a maximum of 16,000 rpm.

After the Dieselgate story hit hard VW’s sales across the world, the company made significant investments in the development of e-cars, not only to strengthen its positions in environmentally-friendly automotive technologies, but also to revive its reputation. One of the main challenges for VW engineers during the development of this EV gearbox is to ensure absolutely noiseless operation, as the level of noise plays a significant role for comfort of the driver and other passengers. Thus, all elements of this 1-speed unit had to be produced with the utmost precision to prevent any additional noises. Each e-drive system is exposed not only to comprehensive performance tests, but also to noise level checks.

VW plans to invest more than $30 bln into the development of EVs by 2023, which is approximately equal to the combined profit of VW for several years. Analytics of the German company predict that in a few years the brand will significantly increase its EV sales revenue.

Tips to Select the Right Engine + Transmission Combination for a Truck

Wed, 26 Feb 2020 13:00:00 -0700

Tips to Select the Right Engine + Transmission Combination for a Truck

A fleet truck can be easily overloaded if it does not come with the proper powertrain (engine+ transmission) combination, thereby resulting in increased expenditures for maintenance servicing. The combination of these components plays a critical role for the truck performance capacity.

There is no standard solution when it comes to choosing the perfect powertrain for any truck. In this article, we will consider some helpful tips for owners of truck fleets on selecting truck components that have a significant impact on its performance, fuel economy and maintainability.

Application target

The first question that has to be clarified during the quest for a perfect powertrain system is the future application of the truck. When talking about the truck application, it is necessary to consider such factors as truck’s operating weight, max possible starting grade, and designated road surface help to specify what transmissions and engines will make your truck a real asset for any business. It should be noted that there are some transmissions that have certain restriction concerning the GCVW rates. All these important parameters mentioned above help to determine what kind of gearing and torque will be needed to operate most efficiently at specific cruise speeds.

Significance of Drivability

One of the most important aspects for truck drivers is the drivability of the vehicle. Depending on the application, it is necessary to take into account a wide range of parameters (smoothness of operation, maneuverability, speed of gear shifting, availability of creep mode) that ensure safe and efficient operation of the truck. For instance, it is extremely important for ambulance/fire and emergency vehicles to shift gears and pick-up the speed as fast as possible. In applications that are frequently exposed to stop-and-start traffic, it is necessary to pay attention to such aspects as clutch wear and driver fatigue (in such cases automatics may be more preferable).

Engine Displacement

The requirements imposed on the engine displacement greatly depend on the vocation of a specific truck. For example, trucks used for transportation of heavy loads may benefit from using a smaller engine displacement in order to save weight. Fleet managers should collaborate closely with dealers to determine the required engine size and to come up with the most efficient powertrain combination.

Manual vs Automatic

Selecting an ideal transmission type is crucial when considering a particular kind of fleet operation. When it comes to choosing between manual and automatic gear shifting units for trucks, it is necessary to keep in mind the following aspects: vehicle application, driver’s expertise, main characteristics of the engine (power, torque).

Truck drivers with different professional competence levels have recently been giving preference to automatics because of numerous advantages of modern self-shifting solutions. Automatics free drivers from the necessity to constantly engage the clutch pedal and shift gears manually, thereby allowing them to concentrate on the road and reduce the possibility of road accidents. As the global automotive industry gradually shifts to complete automation regarding transmission solutions, owners of truck fleets also cannot ignore the fact that new heavy-duty automatic gearboxes outperform conventional manuals in several important aspects (from performance capacity to maintenance cost).

Direct-Drive or Overdrive

Once the transmission type has been specified, fleet owners have to decide on a direct-drive or overdrive configuration. Until recently, overdrive options have been enjoying much more popularity. The thing is that previously the automotive market offered a limited number of direct-drive manuals on the market, and there was restricted axle ratio coverage to work with the direct-drive. But most of modern AMTs come in both direct and overdrive configurations. In fact, direct-drive units are more fuel efficient than their overdrive analogs.

Performance and Economy

Another important factor to consider when determining the main powertrain components is the priority between the performance and economy of the fleet truck. If good performance characteristics allow drivers to feel more comfortable on the road, high economy rates allow businesses to reduce the overall cost of operations. Achieving the right balance between these two important parameters is a big factor when determining the right powertrain setup.

Drivers

Driver satisfaction also should not be disregarded in this important design aspect. The right powertrain is not just about the performance and economy ratio. The correct combination should allow the driver to operate the truck in the most comfortable way possible, thereby avoiding excessive fatigue and increasing safety on the road. The competence and flexibility of drivers can differ, depending on the kind of fleet and peculiarities of the business. In fact, most of the drivers now are reluctant to drive manual trucks or simply don’t know how to do it. When considering the powertrain configuration, it is important for fleet owners to understand the level of driving skills of their employees.

Learn what it is like to drive a truck equipped with an AMT transmission and how’s it different from manual truck experience

Resale Value

Finding the appropriate powertrain setup also should be examined from the resale perspective. It is not a secret that major vehicle manufacturers gradually shift from manual to automatic transmissions, and it has a significant impact on the used vehicles market. Currently, automatic trucks have a higher resale value. When it comes to the engine, the choice between diesel and gasoline-powered engines depends on qualities for a specific business. While diesels ensure longer operation and better fuel economy, while gasoline engine vehicles are notable for a lower upfront cost.

Summary

All in all, a proper selection of the main powertrain components, namely engine and transmission, cannot be performed separately, as both components are interdependent when it comes to ensuring the highest performance and economy rates. Moreover, it should be born in mind that operating characteristics must match application peculiarities of the truck.

Eaton Updates its IntelliConnect Diagnostics Solution

Tue, 25 Feb 2020 13:00:00 -0700

Eaton Updates its IntelliConnect Diagnostics Solution

Eaton has recently announced a range of modifications to its IntelliConnect remote diagnostics system, which allows drivers and fleets to receive relevant data on with fault codes, prioritizes critical issues and offers possible corrective measures. The introduction of new features is expected to become a significant step in workflow optimization.

Learn more about this diagnostic system designed by Eaton

First of all, the list of upgrades includes a new report type on the operating condition of fleet transmissions as well as a special report on the full list of fleet vehicles requiring any kind of transmission servicing. From now on, users of the Eaton’s diagnostic system will be able to add and update fleet info by uploading information files, and simultaneously update and add data on numerous vehicles to the database.

A fleet page used by users for monitoring all fleet vehicles and fast identification of faulty vehicles, now will make it possible for users to create a watch-list based on different parameters of the vehicle. Moreover, a seven-day severity feature will utilize a special icon to display the most serious error codes that have emerged within a week.

Users can select priorities for service issues on the basis of seriousness of error codes

The updated system provides access to the latest product info library, granting access to online troubleshooting and product service manuals. Links to particular error code troubleshooting pages will free users from the necessity to perform time-consuming searches via large PDF files. New system updates facilitate the work of fleet administrators and allow them to detect vehicles with possible repair issues and work out possible solutions in the most prompt and efficient manner.

Allison’s New RHS Transmission Earns a Prestigious Award

Mon, 24 Feb 2020 13:00:00 -0700

Allison’s New RHS Transmission Earns a Prestigious Award

Allison’s transmission solution 3414 RHS is a good example of how automotive market needs facilitate progress of Allison products. Developed in accordance with the latest industry trends and demands of modern customers, the 3414 RHS unit is now gaining recognition from industry experts. Heavy Duty Trucking magazine named this remarkable transmission solution a Top 20 Product Winner for 2020.

According to the magazine, this new transmission deserves this award, as it combines a wide range of advantages (lightweight, robustness, productivity) that are valued by the customers. Considered to be an ideal transmission option for urban delivery tractors, this innovative unit was closely examined by professional advisory board to comply with the award’s criteria.

Allison 3414 Regional Haul Series™ (RHS) transmission

As a part of the Allison’s 3000 Series, the 3414 RHS unit is the lightest solution in the segment and has increased enhanced performance characteristics (410 hp and 1966 Nm). Thus, this powerful gear shifting unit can be successfully used in fleet trucks operating in mixed duty cycles.

Compared to AMT analogs, the 3414 RHS unit ensures much faster (up to 25%) speed-up capacity. Moreover, by utilizing Allison’s xFE feature, which comprises an internal gear algorithm adjusted for increased fuel efficiency, and FuelSense® 2.0 with DynActive feature, this transmission guarantees improved fuel saving (up to 8 %).

This product is backed by Allison’s 5 year/ 750,000 miles warranty, including towing services. Since there is no necessity to frequently deal with clutch repairs like in manual trucks, fleets with Allison-equipped vehicles can forget about unplanned downtimes caused by frequent clutch issues. Allison officials have no doubts that this promising transmission solution will gain extreme popularity among fleet owners, as this unit combines some unique characteristics (lightweight and productivity rates) with the proven durability of Allison products.

Hyundai and Kia Develop a Unique Gear Shifting Technology

Sun, 23 Feb 2020 13:00:00 -0700

Hyundai and Kia Develop a Unique Gear Shifting Technology

Two major Korean automakers Hyundai and Kia have designed a predictive Information and Communication Technology (ICT) Connected Shift System, allowing the car to switch automatically to the most appropriate gear after assessing the road and traffic situations ahead. Both automakers plan to utilize this promising technology on their future models. It is interesting to point out that during development process, the companies managed to file numerous patents.

The new product is the 1-st ICT solution that shifts gears automatically on the basis of the road situation. The new system utilizes smart software integrated in the TCU unit that gathers and analyzes real-time info from different systems (cameras, cruise control radar, 3D-navigation). Using all this relevant data from different sources, the TCU specifies the greatest shift scenario for the current road situation via an AI algorithm and switches gears respectively. For instance, when a relatively long-time speed reduction is to take place and radar does not discover any speed changes with the vehicle ahead, the system switches to N gear for some time to optimize fuel economy.

During practical tests of a car equipped with the new system on a heavily twisted road, the rate of shifts in cornering was decreased by about 43% in contrast to cars without the system. At the same time, the system also helps to lower the frequency of brake engagement by more than 10%, thus making the process of driving more comfortable and reducing brake wearing to a minimum.

When prompt speed-ups were necessary to drive into a highway, the system switched to Sport Mode at the merge, simplifying the process of joining the traffic stream. After merging with traffic, the car independently engaged the original driving mode, ensuring safe and efficient driving. Moreover, the engine brakes were automatically engaged after release of the gas pedal by detecting speed control bumps, downhill slopes and road sections with speed limitations. Distance variations from the car ahead were measured by the front radar to engage the proper gear automatically, which positively affected driving experience.

Both automakers plan to continue enhancing capacities of the new shifting system. Companies didn’t give any specific details regarding particular dates when the new system will find application in production vehicles.

Jasper Collaborates with Find A Wrench

Fri, 21 Feb 2020 13:00:00 -0700

Jasper Collaborates with Find A Wrench

Jasper Engines & Transmissions, the largest US remanufacturer of drivetrain elements, and Find A Wrench (FAW), have entered into partnership to offer tools and services for independent workshops, and dealer centers, experiencing labor shortages.

Find A Wrench cooperates with independent workshops and other automotive companies across the US territory, assisting them hiring talented and skilled specialists and work out strategies aimed at resolving their staff shortage issues. FAW helps companies to find specialists with specific skill-sets, allowing business owners to concentrate performing their direct duties. The joint initiative, named FAW 4-Speed Recruiting, helps with headhunting via job boards, social recruiting, personalized outreach and talent attraction.

Thanks to an innovative virtual reality (VR) training technology designed by Bosch, Ford automotive repair specialists soon will learn how to service and maintain the fully electric Mustang Mach-E without the necessity to get inside the car. Thanks to such approach, young repair specialists will become familiar with design peculiarities of Mustang Mach-E, including SUV’s high-voltage unit, via a simulated environment, thus the presence of the actual car is not necessary.

This sophisticated VR training tool allows specialists to learn more about specific vehicle elements and measures needed to properly service these high-tech mechanisms, and perform professional diagnostics procedures. The tool is complemented with the VR headset for technicians to undergo training and perform special tasks, which include teardown and mounting of the main battery unit as well as related maintenance services.

Bosch also contributes to the development of VR technologies for the auto repair world, which will allow mechanics to navigate through automotive modules to closely examine the main automotive mechanisms. It allows young techs to detect the source of the possible issue and to come up with the most efficient solution. The VR training technology is a new approach to providing more efficient repair services. By bringing the process of diagnostics to a new level, technicians can provide maintenance and repair services more quickly and effectively.

Check out how advanced Bosch tools can help repair shops

This innovative VR technology can be utilized as a permanent training tool, allowing repair specialists to grasp necessary skills in the Ford tech training program. Ford and Bosch representatives assume that the VR training technology has the potential to attract talented young people to the automotive repair world by changing archaic ways of looking at the repair business thanks to introduction of high-tech solutions.

Bosch came up with the VR concept for the repair training in 2019, and then successfully tested it in practice. Ford is the 1-st automaker to try out the application in its powertrain repair training, specifically with the all-new Mustang Mach-E, the company’s first fully-electric SUV. Ford does not exclude the possibility of expanding the technology use to train on other vehicle models in the future.

FCA Recalls Ram Heavy Duty Trucks Because of Possible ATF Leak Issue

Mon, 17 Feb 2020 13:00:00 -0700

FCA Recalls Ram Heavy Duty Trucks Because of Possible ATF Leak Issue

FCA has recently issued a recall for its 2019 and 2020 Ram 2500 and 3500 trucks because of ATF leakages from the automatic transmission, which resulted in 19 fires and 1 injury. Both trucks come with the 6-speed 68RFE automatics.

2019 RAM 2500

According to materials presented by the responsible authority (NHTSA), ATF can be squeezed out of the dipstick tube because of excessive pressure and heat within the gearbox, causing the fluid to contact the turbochargers or other ignition sources and increasing the risk of flame formation.

2020 RAM 3500

The automaker started an investigation regarding numerous cases of engine compartment fires in Ram 2500 and 3500 at the end of last year. After a detailed examination of witness reports and design specifications of both trucks, FCA specialists managed to detect the source of the problem. It is said that prior to the fire outbreak, RAM drivers may hear noises or sense strange odors.

6-speed 68RFE automatic transmission

According to the official documents, the recall list includes 84,978 Ram trucks. FCA plans to launch the recall campaign in the middle of March. To fix this life-threatening issue, dealerships plan to replace the valve body separating plate and reprogram the powertrain control module.

Learn more about the 68RFE transmission

This particular recall includes only models with a specific powertrain combination: the 68RFE unit coupled with the 6.7-liter Cummins TD engine. Versions of the recalled trucks with different powertrain configurations aren’t involved in this campaign.

Anand Group Inks Tech Alliance with Mazaro for Energy-Saving Transmissions

Sun, 16 Feb 2020 13:00:00 -0700

Anand Group Inks Tech Alliance with Mazaro for Energy-Saving Transmissions

As the electrification trend gains momentum in the automotive industry, Anand Group, the leading manufacturer of spare parts in India, plans to make significant investments in development of advanced technology solutions. Along with strategic collaboration with Far-UK for the use of carbon fibre structural composites intended for vehicle weight optimization, the company has recently entered into a partnership with the Belgian company Mazaro, which is aimed to enhance efficiency of transmission technologies in India.

Both parties have joined efforts to bring on the Indian market innovative gear shifting technologies (called “revolutionary transmissions”) that are supposed to decrease the level of harmful emissions. This know-how has the potential to decrease energy consumption in cars equipped with IC-engines and EVs by up to 18%. The collaboration plans to target sales from four-wheelers used for last-mile connectivity, city transport, across segments, as well as in off-highway applications.

MAZARO’s Reversible Variable Transmission (RVT) intended for RWD vehicles

MAZARO’s Single Stage Variable Transmission (SVT) intended for E-truck

Mazaro is well-known on the European market for manufacturing of sophisticated transmission solutions (RVTs and SVTs) that combine impressive internal efficiency rates with the capacity to keep the engine or e-motor on its optimal efficiency curve at all times, enhancing operating characteristics and comfort. The solution with almost zero slippage and insignificant wear characteristics, will be adjusted to vehicle platforms in India that are notable for frequent gear shifts and demand increased start-up torque.

The revolutionary transmission, without gears or belts, allows vehicles to transfer power to the wheels in more efficient manner -- either IC-engines or E-powertrains -- by replacing the gearbox. It is said that a driver used to either a 5-speed manual or 7-speed automatic, would experience the feel equivalent to possibly an 11-speed automatic transmission. This results in increasing the range of the vehicle for EV and fuel economy for IC-engine driven cars.

According to Mazaro’s officials, the combination of Anand’s manufacturing capabilities with Mazaro’s top-notch engineering concepts is the right way to provide revolutionary solutions to the Indian transportation sector to meet the requirements of a wide variety of potential applications, both in electric and ICE models.

ANAND Group representative, in turn, confirmed the company’s commitment to development of environmentally-friendly automotive technologies and its aspiration to collaborate with automotive professionals from all over the world and provide the Indian OEMs with advanced solutions. The partnership with Mazaro fully complies with Anand Group’s vision and approach to development of efficient gearboxes for the Indian market.

New Indian Military Vehicle Comes with Allison Transmission Unit

Fri, 14 Feb 2020 13:00:00 -0700

New Indian Military Vehicle Comes with Allison Transmission Unit

Allison Transmission, the world-renowned provider of automatic transmission solutions, supplied the Allison X1100-5A3 unit for the military project in India. As a part of this project, the Indian company L&T has recently supplied the first batch of 51 K9 Vajra-T tracked self-propelled gun systems equipped with Allison Automatics to the Indian military forces before the agreed schedule. It is expected that the remaining part of the machines will be delivered by the end of this year.

X1100-5A3 Series transmission

Allison’s X1100 Series is a cross-drive transmission intended for either military or heavy-duty tracked vehicles. This sophisticated gear shifting unit is a tangible embodiment of the Allison’s solid experience and expertise accumulated thanks to the company’s long-time cooperation with the military sector. Enhanced performance capacity and robustness of these automatics under severe operating conditions allowed Allison to gain recognition in the global military industry.

K9 Vajra-T

Powered by the 1,000 hp diesel engine, the K9 Vajra vehicle is operated by a five-man crew. Weighing about 50 tons, these military vehicles can fire 47kg shells at 43-kilometre distant targets. It can also turn around at zero radius. The reliability and enhanced maneuvering capacities of the Allison X1100 unit is perfect for military applications that must operate properly in roughest environments.

Allison has been closely collaborating with military companies all over the world since 1946. For companies specialized in manufacturing of military machinery, Allison offers an individual approach to each customer and a wide range of options for product customization. Moreover, the company has recently participated in the DefExpo expo in India, where the company’s representatives presented in more depth the advantages of Allison solutions for military vehicles. This international exhibition dedicated to the latest achievements in defense technologies.

Ricardo Provides DCT Transmission Software for CEVT

Thu, 13 Feb 2020 13:00:00 -0700

Ricardo Provides DCT Transmission Software for CEVT

Ricardo, a British-based engineering company, has recently taken an obligation to manufacture and supply transmission control software for a 7-speed DCT unit for CEVT, a Swedish-based innovation center specialized in mobility technologies for the Geely Group brands. It is planned that the new software will find application in a 2020 compact luxury crossover.

According to Ricardo, the software has been created on the basis of a ‘systemized track’ approach, in which the vehicle level specifications helped to specify the software of the gearbox control unit. Moreover, it is said that the software complies with the industry standard ‘A-Spice Level 2’. This included thorough testing at different levels, and providing complete traceability between the specification of each vehicle-level requirement, testing procedures and results.

Moreover, it is alleged that the new software also corresponds to the international standard of functional safety to provide in-built monitoring feature. Thus, in case of any software/hardware failure, the maximum operational availability of the gearbox will be maintained, while also taking into account its safe operation.

The process of software development for automobiles demands a well-thought and systemic approach to guarantee the necessary level of operational efficiency, fault-tolerance and safety, while also ensuring the required level of flexibility. Ricardo has already made a significant progress in this direction, but cannot afford to become complacent, as the software requirements become more complicated with rapid development of electric and hybrid vehicles.

Learn more about driveline and transmission systems provided by Ricardo

CEVT has highest regard for professionalism of its English colleagues, as Ricardo always timely provided the necessary software releases for testing. Therefore, it became possible to fix all critical faults before the production launch.

Trucks Equipped with Allison’s Automatics Show Impressive Results in Major Rally Raids

Tue, 11 Feb 2020 13:00:00 -0700

Trucks Equipped with Allison’s Automatics Show Impressive Results in Major Rally Raids

Strengths of Allison automatic transmissions compared to AMTs and manuals proved to be highly efficient during the two recent rally raids known for rough conditions. Allison-equipped trucks claimed the most of top 10 positions in the truck segment on the Dakar Rally 2020, and in a couple of days an Allison-equipped Scania truck celebrated a victory in the Africa Eco Race (AER) competition.

Decent results in these prestigious competitions showed that in practice Allison’s automatics can be more efficient than alternative transmission solutions. Thanks to the use of advanced automatics, drivers could compete more comfortably and safely, as there was no need in shifting gears manually and they could concentrate on driving via heavy-going and sandy surfaces. And that is why Allison’s solutions gradually gain popularity in endurance competitions.

AER is an annual racing competition arranged in North of Africa, as response to the cancellation of 2008 Dakar Rally, and its subsequent relocation, for those enthusiasts who desired to compete in the spirit of the true Dakar. The route of this 6,500 km race went through the territories of several African countries with 12 racing stages. The raid was won by the Scania Torpedo of Qualisport Racing Team. The truck’s powerful engine delivered its 4,700 Nm of torque via a 4000 SeriesTM Allison transmission.

Allison’s 4000 Series Transmission

Miklós Kovács, the winner of the race, candidly expressed his delight with operating qualities of his automatic car, especially its transmission unit. During attention demanding racing battles through hard-to-pass dunes, Miklós managed to concentrate on the road, while the gearbox smoothly and timely shifted gears. Thanks to well-adjusted operation of the whole powertrain system, the victorious truck successfully passed the trickiest parts of the route.

Scania Torpedo truck at the Africa Eco Race

This year, the legendary Dakar Rally was hosted in Saudi Arabia for the 1-st time in its history. About 50 racing trucks were exposed to extreme weather conditions over a 7,800 km route. When the most tenacious participants crossed the finish line, trucks equipped with Allison’s automatics were among.

Check out highlights of the 2020 Dakar rally raid

The 4000 Series solutions are intended for heavy trucks and ensure smooth and efficient operation. These units are notable for exceptional performance characteristics and enhanced reliability. Options with close and wide ranges of gear ratios and availability of an optional PTO greatly facilitate the driver’s work. The transmission unit can have up to 7 speeds, including 2 overdrive ratios and a 2-nd R gear. Operating characteristics of the gear shifting unit are further enhanced by the latest electronic controls.

Nidec Plans to Focus on EV Powertrains

Mon, 10 Feb 2020 13:00:00 -0700

Nidec Plans to Focus on EV Powertrains

According to unconfirmed reports, the Japanese company Nidec Corp expects to significantly increase its earnings over the next 5 years by strengthening its presence on the automotive market via significant investments into production of powertrain solutions for EVs and takeovers of businesses specialized in e-motor solutions.

Reuters, citing unnamed sources familiar with Nidec plans, says that in the coming years the company intends to significantly increase the share of income from the sale of e-motors and integrated solutions for the auto industry. If we are talking about specific numbers, it is claimed that Nidec’s plan is to increase the annual earnings up to $46 bln in 5 years. The EV niche is expected to become one of Nidec’s main sources of revenue growth.

Nidec’s powertrain E-axle

Another important direction for further growth in the automotive business is to optimize production processes related to powertrain (also referred as e-axles) solutions for EVs. The company plans to boost the quality and operating characteristics of its e-axles, making them more effective, compact and thus cheaper. In December last year, former Nissan Deputy Director of Operations Jun Seki joined Nidec as president of the corporation. This step further emphasizes the company’s focus on the needs of the automotive market.

Nidec already produces xEV powertrains, including e-motors, power electronics and gearboxes in volume. In Europe, the company closely collaborates with PSA Group, which opened its e-powertrain assembly line at the Trémery engine plant in France at the end of last year. Nidec is an important partner in this initiative. In China, Nidec is providing e-axle solutions to GAC's Aion S all-electric sedan. Nidec and GAC also have entered into a joint-venture agreement to produce the e-axles in China. Nidec is expected to become a serious competitor to major e-axle providers such as Germany’s Bosch and ZF.

Learn more about Nidec and its products

It is predicted that production vehicles based on environmentally-friendly technologies will reach 13.3 mln in 2026. Automotive analysts report that the key objective for Nidec will be to get costs of e-axles down to roughly $1,500 or below from the current $2,000, while also enhancing their performance characteristics.

MAHLE Aftermarket to Sell More Automotive Products in Canada Thanks to a New Partnership

Mon, 10 Feb 2020 13:00:00 -0700

MAHLE Aftermarket to Sell More Automotive Products in Canada Thanks to a New Partnership

MAHLE Aftermarket Inc. has entered into partnership agreement with Grant Brothers Sales (GBS) Ltd., one of Canada’s biggest manufacturers’ representatives. This cooperation allows MAHLE to strengthen its positions on the Canadian market and to supply its products more efficiently to the local customers.

MAHLE will cooperate closely with the GBS’ sales and customer service specialists to provide its Canadian customers with a wide range of automotive products, from diagnostic and service tools to quality spare parts.

Learn more about MAHLE Aftermarket and its products

MAHLE officials are very enthusiastic about collaborating with GBS, as it is a great chance for MAHLE to consolidate its positions on the Canadian market. The MAHLE brand has gained recognition all over the world for top-quality powertrain components. The company is also known for a wide range of special solutions for maintenance and servicing. MAHLE Aftermarket is one of four divisions of MAHLE GmbH, one of the biggest providers of car components around the globe. In 2020, the company has established a new electronics and mechatronics business unit. Moreover, this year the company celebrates a 100-year anniversary of being the part of the global auto industry.

MAHLE and GBS teams during the recent meeting at MAHLE headquarters

Thanks to its service offerings, GBS managed to establish crucial ties with the aftermarket businesses in Canada. It will certainly help MAHLE to provide potential Canadian customers with advanced products, including exceptional support and tech training. Both parties have already started close cooperation to prepare a 2020 sales strategy.

The Canadian aftermarket is a promising business niche, and this new partnership will make it possible to offer customers advanced solutions and innovative technologies. Add to that a great reputation of GBS in this business, and it is possible to see a great potential of this partnership.

Donaldson Presents New Powertrain Vents

Sun, 09 Feb 2020 13:00:00 -0700

Donaldson Presents New Powertrain Vents

Donaldson Company, a major supplier of filtering solutions, has recently released new protective vents designed to save automotive powertrains from contaminating agents and pressure loads.

The company now offers 4 new products – the Screw-Fit and 3 Hose-Fit Powertrain Vents – that ensure optimized assembly and enhanced vent service life for vehicles working under severe conditions. Designs of these vents are notable for presence of unique oil-coalescing pre-filters, ensuring airflow maintenance. Powertrain vents (PV) are extremely helpful when it comes to protecting a car’s gearbox, axles and other elements from negative impacts and control pressure alterations that can affect some housing elements.

Donaldson powertrain vents

PVs play an important role in operating characteristics and durability of cars, but standard vent hoses have been quite complex to install and they usually get clogged with lubricants. Donaldson’s space-saving solutions can be easily incorporated into any powertrain unit, and their special pre-filters help them to operate longer and perform more efficiently than any analogs currently available on the automotive market. Moreover, new solutions are more compact than standard analogs.

To solve the most challenging issue related to car venting – an accumulation of lubricating film that decreases venting airflow – company’s engineers equipped new vents with a coalescing pre-filter. By effectively filtering oil particles, Donaldson vents ensure better operating characteristics and prolonged operating life. The new offerings will compliment Donaldson’s solid auto portfolio, which includes a wide range of venting products for other car units.

The IVS business unit of Donaldson works on venting technologies to keep the main automotive components safe from debris, lubricants and other liquids, at the same time ensuring pressure balancing in and around components. Thanks to the high level of professionalism and top-quality products, the company managed to earn a great reputation in numerous industries.

ZF Aftermarket Develops New Clutch Kit and Marks Its Long-Time Presence in Motorsports

Fri, 07 Feb 2020 13:00:00 -0700

ZF Aftermarket Develops New Clutch Kit and Marks Its Long-Time Presence in Motorsports

ZF Aftermarket has always been devoted to satisfying the needs of its customers by providing innovative and efficient solutions. Under its SACHS brand, ZF Aftermarket has presented an improved clutch kit intended for performance-oriented cars and those operating under severe driving conditions. To demonstrate how engineering concepts are converted into serial products, and to mark the 80-years’ presence in motorsport, the company has invited 3 well-known racing drivers to participate in the new “Brand Ambassador” initiative.

Joachim Waagaard, Billy Monger and Christian Engelhart

SACHS products developed an outstanding reputation among racing drivers, but as a pacemaker in the area of advancing mobility solutions, ZF frequently readjusts its racing technologies to be applied for manufacturing of components used on road cars worldwide. The new improved SACHS clutch kit brings ZF’s know-hows into everyday life.

Designed particularly for high performance applications, the new kit comprises a clutch pressure plate, clutch disc and release bearing. The range was initially designed for Subaru diesel models with the year of manufacture from 2008 onwards. The reinforced diaphragm spring ensures prolonged operating lifespan and better contact pressure, which enhances robustness of the gearbox and lower friction wear.

ZF’s reinforced clutch kit

The brand has been presented in the racing world since 1937 when the design of the 1-st Mercedes “Silver Arrows” was complemented with SACHS spare parts. SACHS’s products also gained recognition in Le Mans and F-1 competitions. Nowadays, ZF’s collaboration with motorsport is not limited to supply of quality parts, but also includes technical support. Two ZF tech teams travel around the world during the racing season, recalibrating absorbers and fixing clutches. Providing engineering support at racing events around the globe, ZF experts contribute to successful results of teams supported by ZF.

Unusual Gear Shifting Solutions in Hurst/Olds Сars

Thu, 06 Feb 2020 13:00:00 -0700

Unusual Gear Shifting Solutions in Hurst/Olds Сars

Today, it may be hard to believe today, but in the 80s, GM amazed the automotive market with cars with remarkable gear shifting mechanisms. These remarkable shifters allowed drivers of automatic cars to shift gears manually.

In 1968, Oldsmobile, in cooperation with Hurst Performance, produced a special version of the Olds Cutlass Supreme, named the Hurst/Olds. The most remarkable feature of this car was neither the paint job nor its powerful engine, but a Hurst dual-gate shifter that offered two algorithms of gear shifting. Before this unique project, George Hurst offered his remarkable gear shifting solution in 1963. It was supposed to make it possible for muscle-car drivers to shift gears more rapidly than with standard automatics.

Hurst dual-gate shifter

The Hurst shifting technology was based on a simple engineering concept - a shifter with 2 paths. The main left shift pattern was a conventional PRNDL (automatic) mechanism where you shift the lever in D gear and let the gearbox do the trick. It operated with medium line pressure and quite low shift points for comfortable driving. The other gate was intended for a synchronized manual control.

It implies that drivers of that time had a genuine choice. They could drive comfortably without troubling themselves with shifting gears (automatic mode) or to be more involved in the inner workings of their vehicle (manual mode). They could rely on the control system to do the job for them or to trust their own reflexes. It was also known as "His 'n' Her" shifter, as female drivers preferred to drive automatically, while men more often opted for the manual control.

In 1983 GM released the car with even more unusual gear shifting mechanism named Hurst Lightning Rods Triple Shifter. This technology has found application on the special Cutlass Supreme version.

Hurst Lightning Rods Triple Shifter

For futuristic gear shifter design, Hurst engineers took inspiration from the Lenco gear shifting technology that gained popularity in the world of drag racing. The design of Lenco unit comprises a series of planetary gear assemblies with a modular arrangement. The engineering structure of this transmission included a shift lever for each gear set. Hurst used this race-only setup as a basis and adjusted it to conventional automatics, making it possible for common auto enthusiasts to feel like a professional racer.

Lenco 4-speed drag racing transmission

The Lightning Rods solution was conceived to operate like any standard automatic gear shifter, with a well-known PRND pattern. The most peculiar part of its design lied in 2 extra levers. No wonder that such unusual design solution frequently confused young drivers, so Hurst made sure the system had a means of being driven even by inexperienced drivers: it was necessary to push the center and right lever forward to switch the gear shifting process into automatic mode.

Designed to be visually fascinating as Lenco, at the same time allowing manual shifting in the automatic car, the Lightning Rods system became a truly unique technology. These shifters sold in limited quantities by Hurst at speed shops throughout the US, but their expensiveness kept volume low. Moreover, this miracle of automotive engineering also found application in ’83-84 Oldsmobiles.

Check out this 3 lever shifter in action

Unfortunately, these 3-lever shifters turned out to be commercially unviable, and after ’83-84 Olds, this technology became a part of the automotive history. Hurst tried to revive this technology introducing aftermarket kits, but this idea also had poor success. Eventually Hurst shifting technology was replaced by more efficient shifters (Ratchet, Manu-Matic).

Geely’s New Dual-Clutch Transmission Finds Application in Malaysia

Wed, 05 Feb 2020 13:00:00 -0700

Geely’s New Dual-Clutch Transmission Finds Application in Malaysia

Proton, a Malaysian automotive company, has recently announced that the new X70 SUV model will be equipped with a 7-speed DCT transmission, and before its official release, the automaker invited a group of media reporters to China for the purpose of learning more about the new transmission solution. The wet clutch unit, designed by Geely together with Volvo, is being produced at 2 Geely’s manufacturing facilities in China, and it has already found application in some vehicle models.

The new gearbox is claimed to be the same dimensions as 6-speed automatics and weighs less (only 75 kg). The transmission comes with a special shift-by-wire electronic gear lever and paddle shifters. It can shift gears pretty fast (0.3 seconds per shift) and has a maximum torque capacity of 330 Nm.

Boyue Pro drivetrain

It is said that the DCT provides unmatched efficiency rates, as the new solution actually outperforms VW’s dry clutch DSGs, at the same time ensuring lower driveline losses than German wet clutch units. The overall efficiency rate of the Geely solution is close to parameters of conventional manual shifters, and it allows the Geely’s Boyue Pro to stand out on the Chinese automotive market for its enhanced fuel consumption rates. Geely says the new DCT is also more efficient than some of Aisin’s automatics.

Putting aside the question of efficiency, it is well-known that VW’s dry clutch DSGs have a bad reputation when it comes to durability. Geely, in turn, claims that its engineering specialists in cooperation with their Volvo colleagues managed to avoid VW’s mistakes. The new transmission fully complies with Volvo’s stringent durability regulations, ensuring a service life of more than 350,000 km. The new gearbox was also subjected to a wide range of field tests under severe weather conditions in various countries. All in all, total distance covered by the test team reached over nine million kilometers.

Moreover, efficiency and durability of the new DCT will be enhanced by the use of patented low-viscosity technology. This is especially important as DCTs require a different lubricant that significantly differs in operating properties from traditional ATFs. At the same time, servicing intervals for the new DCT are similar to conventional automatics. The upcoming 2020 Proton X70 CKD is the 1-st vehicle jointly constructed by PROTON and Geely and is the 1-st Proton model in the premium SUV segment.

FCA Recalls Ram ProMaster Vans Because of Transmission Issue

Tue, 04 Feb 2020 13:00:00 -0700

FCA Recalls Ram ProMaster Vans Because of Transmission Issue

FCA has recently issued a recall of more than 222,000 model year 2014-2019 Ram ProMaster vans because of the transmission problem, namely shifter cables may detach from the transmission unit. As a result, the vehicle may not change gears as the driver intends, i.e. the lever position won’t match the engaged gears, thereby creating the possibility of unsafe situations on the road. Over the last few years, different FCA models have been subjected to major recalls caused by transmission issues.

It is claimed that the affected Ram vans may have been built with transmission gear shift cables that were twisted during the assembly process. If the shift cable separates, the shifter is no longer attached to the transmission. The driver, then, may be confused with the transmission performance. If the driver thinks the vehicle is parked, but, in fact, it is still in D or N, the vehicle may roll away causing life-threatening situations.

2019 Ram ProMasters and its Interior

No warning signals appear if the shifter cable disconnects from the gearbox. However, after the cable comes off, the driver may notice that the shift lever can be moved with much less efforts. FCA has already informed the responsible authorities (NHTSA) that it has no info on any road traffic accidents or injuries and has no field reports of issues related to the condition. The automaker has received 545 warranty claims.

That’s how transmission gear shifter cable looks like

The recalled vans with faulty transmissions were produced in Saltillo, Mexico, between April 23, 2013, and Sept. 14, 2019. Similar 2014-2019 model year Ram ProMasters with other engines or those built after modernization of a production process in September are not included in the recall. Approximately 3% of the recalled vehicles are assumed to have the cable malfunction.

FCA first found out about a possible problem in May 2019 when the carmaker started investigating the issues. The actual recall is assumed to be launched at the end of next month. Ram dealers will replace the shifter cable absolutely free-of-charge. Customers who paid for the repair related to the shifter issue will be compensated. As a safety precaution until the vans are properly diagnosed and repaired, FCA encourages owners to use the handbrake when parking these vehicles.

Eaton Expands Its PTO and Clutch Lines

Mon, 03 Feb 2020 13:00:00 -0700

Eaton Expands Its PTO and Clutch Lines

During the recent HDAW exhibition, Eaton has revealed the details on the expansion of its clutch and PTO portfolios. Advantage Automated Series clutches and two new Bezares PTO solutions will find application in a variety of vehicles and transmissions available on the North American (NA) market. These new solutions prove the company’s intention to provide its American customers with efficient solutions.

The new clutches can be installed in the most common automated gearboxes mostly utilized in NA, including the following:

These robust clutches can handle the unique needs of automated gear shifting units, which find application on more than 75 % of new heavy-duty trucks sold in NA. Designs of these clutches include the following elements: a clutch bracket with a hardened steel pivot ring, which better withstands higher loads, and bigger spring fingers for better wear-resistance when compared to analogs currently available on the automotive market.

Advantage Automated Series clutches

The 95X and 120X Series PTOs intended for Endurant and DT12 units respectively come with aluminum casings to combine heavy-duty strength with light weight. These PTOs are expected to amend installation clearance on the vehicle. One year ago, Eaton reported that one of its division had an agreement with Bezares SA to become its NA authorized distributor for auxiliary hydraulic equipment.

The Bezares 95X series is notable for its lightweight and space-saving design. It features pneumatic shifting and is available with 3 various internal ratios. The offset structure improves the position of a mounted pump to exclude any interference with other vehicle components. The two-gear 120X series PTO fits models DT-12 transmission models. Thanks to its internal ratios, the 120X PTO series connects to the auxiliary systems of the DT12 unit and provides 4 various output variants. The PTO mechanism casing is supposed to improve clearance and simplify the process of installation. Eaton plans to add the Bezares products to its online Order Center, which includes a lot of features helping its customers to find and buy the company’s products.

BorgWarner to Take Over Delphi Technologies

Sun, 02 Feb 2020 13:00:00 -0700

BorgWarner to Take Over Delphi Technologies

BorgWarner Inc. (BW) and Delphi Technologies PLC have recently reached an agreement on a final transaction agreement under which BW will take over Delphi Technologies (DT) in an all-stock transaction that estimates assets of the latter at about $3.3 bln.

It is expected that the deal will strengthen BW’s potential in the field of electrified automotive technologies. Purchasing of DT goes in line with BW’s shifting towards the propulsion market of the future. Upon sealing of the acquisition deal, current BW stockholders are reported to possess about 84% of the combined company, while DT will receive the remaining part of the company stock.

In budget year 2019, BW and DT claim that they accumulated $10.17 bln and $4.36 bln of net sales, accordingly. The combined company is assumed to become one of the top suppliers of vehicle propulsion systems worldwide, providing manufacturers and the aftermarket with highly-efficient and more advanced solutions.

According to BW officials, this promising deal is the next stage in implementation of the company’s development strategy, reinforcing its position in electrified propulsion as well as other automotive segments. DT’ solid experience in power electronics is a fine addition to BW’s current solutions. Joining forces makes it possible for the combined company to deal with challenges related to the global automotive electrification in the most efficient manner. DT’s management team, in turn, puts high hopes on the consolidation of technical capabilities, as both companies share a strong determination to tackle today’s and tomorrow’s challenges of the automotive industry.

Both companies' engine and transmission divisions are considered by experts to be in decline, as car manufacturers actively invest in the development of environmentally-oriented types of vehicles (hybrid, electric). Compelled by governments around the world to enhance fuel efficiency and reduce harmful emissions, carmakers use significant financial resources to electrify powertrains for their future vehicle lines. The industry has also been hit by sluggish economic growth and the U.S. trade war with China. Thus, it is no wonder that some companies resort to mergers & acquisitions to remain competitive on the automotive market.

The acquisition will be beneficial for both companies strategically as well as financially. Potential customers of the reinforced company will be provided with a wide range of advanced solutions in the field of power electronics.

BW analytics hope the combined company to achieve run-rate cost synergies of about $125 mln by 2023 thanks to cost-effectiveness in administrative and procurement operations. The takeover deal is planned to be finalized in the 2-nd half of 2020, once it is approved by DT’s stockholders and gets necessary regulatory approvals.

Punch Powertrain Produces Its 100.000th VT5 Transmission

Sat, 01 Feb 2020 13:00:00 -0700

Punch Powertrain Produces Its 100.000th VT5 Transmission

After the huge success of the VT2/VT3 transmission line in China, Punch Powertrain came up with a series of other innovative solutions. One of them was a VT5 transmission that hit the market just over a year ago. Within such a short period of time, the company managed to produce the 100.000th VT5 unit.

Engineered on the basis of the reliable VT3, the VT5 was designed to be applied on a wider range of cars. It has the torque capacity of up to 280 Nm and has an impressive ratio coverage for a single stage CVT (7.2). It comes with a torque converter, which has a positive impact on the driving experience and incline performance. This gear shifting solution gained popularity among car manufacturers, especially in the SUV segment.

VT5 CVT transmission

In addition, this innovative transmission can be complemented with several optional features, such as start-stop and sailing. Moreover, the VT5 can be equipped with a special shift-by-wire system. It is also known for active controlled dual stage pump as well as innovative secondary shaft-assembly.

Key attributes of this transmission system are the following:

28 mm pushbelt, single mode variator
Increased system pressure, max. 70 bar
Independent pulley pressure control
Reduced drag (cold start & churning loss)

Main elements of the VT5 transmission

This CVT solution is currently supplied to Punch Powertrain customers in China, namely clients Ford-JMC and DFSK. If during the 1-st year of production the main objective was to ensure its high level of quality, the VT5 unit now enters the next phase of its life cycle: introduction of possible modifications and cost optimization. Moreover, the engineering team of Punch Powertrain is currently preparing the release of new product variants, to meet the needs in the rapidly-changing auto market.

Cadillac V-Series to Include Manual Transmission Options

Fri, 31 Jan 2020 13:00:00 -0700

Cadillac V-Series to Include Manual Transmission Options

Manual transmissions seem to become a rare thing in powertrain designs of new cars, but it seems like Cadillac plans to keep stick shifters alive. The continuing story around powertrain details of Cadillac’s upcoming CT4-V and CT5-V models has already created a lot of speculations, and the latest rumors say that both cars will receive well-known GM performance-oriented engines and most interestingly, manual transmissions. Automotive media sources tried to clarify the situation directly with Cadillac, but the company refused to elaborate on the upcoming products.

2020 Cadillac CT5 V

The CT5-V model is expected to be equipped with the 6.2-liter LT4 V-8 that has already found application in some of new Chevrolet models. This engine has the power capacity of 650 hp along with an equal torque rate. It should be noted that the previous models equipped in the "Blackwing" V-8 made just 550 hp in the CT6-V with 850 Nm. Coupled with a manual gearbox, this would be the 1-st time a sporty Cadillac has got such a drivetrain design since 2015 when the CTS-V was taken out of production.

Learn more about Delta Electronics Inc. and its products

GKN has built a solid experience in engineering of eDrive solutions, which has found reflection in the production of more than 1 mln. eDrive units thus far, and this impressive number is constantly growing. DELTA, in turn, has a strong position in power electronics and is currently closely cooperating with the biggest EV manufacturers, offering them its advanced product portfolios.

GKN’s eDrive solutions can be mounted on either the front or rear axle and adjusted for 2WD or 4WD arrangements. Thanks to the fact that 3 main elements of the system are compactly placed in one housing, eDrives are able to ensure smooth operation and increased efficiency when compared to powertrains containing separately packed components.