Transmission Diagnostics & Repair

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type7ATRWD/AWD550-8509,15236.15 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?BrandModelYearTypeEngineMercedes-BenzCLC08-117 SP RWDV6 2.5L 3.5LMercedes-BenzCLK04-097 SP RWDV6 2.5L 3.0L 3.5L V8 5.0L 5.5L 6.3L How to repair this transmission (Videos)722.9 Teardown Inspection722.9 Valvebody Overhaul (TCM) repair part 1 (TCM) repair part 2Transmission, pump damage722.9 TCC adaption Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comDiagnosis, Repair Advanced Training 722.9webwww.at-manuals.comElectrohydraulic control module 722.9webwww.at-manuals.comSolenoid and electronic control identification 722.9webwww.at-manuals.comCheckBalls 722.9webwww.at-manuals.comSolenoids work 722.9webwww.at-manuals.comScheme 722.9pdfSonnaxValve Body Layout 722.9webmercedesmedic.com722.9 7G Tronic Automatic Transmission Problems and Solutions

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type5ATRWD/AWD350, 420, 5809,54236.14 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?BrandModelYearTypeEngineMercedes-BenzVANEO01-055 SP FWDL4 1.7L 1.9L How to repair this transmission (Videos)Teardown InspectionTeardown inspection Part 2Bellhousing Swap & ReassemblyValvebody overhaulB2-B3 Clutch Drum Assembly4Matic Quick TipNAG1 5-Speed Transmission Power FlowPlate Diagnose Instruction manuals and useful linksLink typeSourceDescriptionwebwww.at-manuals.comSchemewebwww.at-manuals.comValve Body 722.6webwww.at-manuals.comSolenoids 722.6 transmissionwebwww.at-manuals.comIdentify type of 722.6 transmission p1webwww.at-manuals.comIdentify type of 722.6 transmission p2pdfSonnaxValve Body Layout 722.6pdfSonnaxVacuum test 722.6/CHRYSLER NAG 1

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type5ATRWD/AWD5808,54236.14 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?BrandModelYearTypeEngineMercedes-Benz300SL90-935 SP RWDL6 3.0LMercedes-BenzS CLASS94-955 SP RWDL6 3.2L How to repair this transmission (Videos)722.5 Mercedes Transmission722.5 Valvebody Overhaul Instruction manuals and useful linksLink typeSourceDescriptionwebwww.at-manuals.comScheme

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATRWD5708,64236.12 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?BrandModelYearTypeEngineMercedes-Benz40092-934 SP RWDV8 4.2LMercedes-Benz50090-934 SP RWDV8 5.0LMercedes-BenzS CLASS94-954 SP RWDL6 3.4L V8 4.2L 5.0L How to repair this transmission (Videos)722.424 Transmission Rebuild722.424 Teardown722 4 Pressure Control cable connection722 424 Valve Body Rebuild722.3 Valve Body Rebuild722.3 K2 Drum Overhaul B1 Piston Cap Tool Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comSchemepdfwww.at-manuals.comTransTec Manualwebwww.at-manuals.comApplication chartpdfjenniskensTransmission Adjustment Guide

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type6DCTFWD4501,81,875w90 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?BrandModelYearTypeEngineFordC-COUPE116 SP FWDL4 2.0LFordC-MAX11-166 SP FWDL4 2.0LFordESCAPE12-166 SP 4WDL4 2.0LFordFOCUS06-166 SP FWDL4 1.5L 2.0LFordGALAXY10-156 SP FWDL4 2.0L 2.2LFordMONDEO08-156 SP FWDL4 1.6L 1.8L 2.0L 2.2LFordS-MAX10-156 SP FWDL4 2.0L How to repair this transmission (Videos) Learning The Getrag's DCT450Hard Parts Identification VideoDisassemble clutchDisassembly and measurement of clutch components Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comScheme 6DCT450pdfwww.getrag.comSpecifications 6DCT451pdfdrive.google.comRepair manual 6DCT450

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type5ATRWD/AWD11,55MerconV 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?BrandModelYearTypeEngineFordTHUNDERBIRD25 SP RWDV8 3.9LJaguarS TYPE00-025 SP RWDV8 4.0LLincolnLS00-025 SP RWDV6 3.0L V8 3.9L How to repair this transmission (Videos)5R55S - Repair - Part - 15R55S - Repair - Part - 25R55N Valvebody Quick tip & Repair5R55S Valve BodyTeardown with code P07755R55S Servo Bore Repair5R55W Servo Bore Repair5R55W TEAR DOWN5R55W SERVO BUSHING INSTALL5R55W SUBASSEMBLY Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.valvebodypros.comInitial Engagementspdfwww.at-manuals.comRepair manual 5R55W, 5R55SpdfSonnaxValve Body Layout 5R55NpdfSonnaxValve Body Layout 5R55S, 5R55WwebSonnaxCheck Balls 5R55W/S

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type5ATRWD/AWD42096Texaco 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?BrandModelYearTypeEngineCadillacSRX03-105 SP R/4WDV6 3.6L V8 4.6LCadillacSTS04-095 SP R/4WDV6 2.8L 3.6L V8 4.6L How to repair this transmission (Videos)Pump Overhaul Initial FindingsShift Solenoid ReconditioningTorque Converter InspectionCone set Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comScheme 5L40webwww.at-manuals.comCheck Balls 5L40ewebwww.at-manuals.comSolenoid application chart 5L40epdfSonnaxValve Body Layout 5L40-EwebSonnax5L40E/5L50-E Loss of Reverse or TCC

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATFWD/AWD38012,77Dexron 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?BrandModelYearTypeEngineBuickCENTURY00-044 SP FWDV6 2.5L 3.0L 3.1LBuickCENTURY00-044 SP FWDV6 2.5L 3.0L 3.1LBuickLACROSSE/ALLURE04-094 SP F/4WDL4 2.4L V6 3.0L 3.6L 3.8L V8 5.3LBuickLESABRE98-054 SP FWDV6 3.8LBuickLUCERNE05-114 SP FWDV6 3.8L 3.9LBuickPARK AVENUE/ULTRA97-044 SP FWDV6 3.8L 3.8L SCBuickREGAL97-044 SP FWDV6 3.8L SCBuickRENDEZVOUS APV01-064 SP F/4WDV6 3.4L 3.5L 3.6LBuickRIVIERA97-994 SP FWDV6 3.8LBuickTERRAZA05-074 SP F/4WDV6 3.5L 3.9LChevrolet/GMIMPALA00-164 SP FWDV6 3.4L 3.5L 3.8L 3.9L V8 5.3LChevrolet/GMLUMINA97-014 SP FWDV6 3.1L 3.4L 3.8L 3.8L SCChevrolet/GMMONTE CARLO97-074 SP FWDV6 3.1L 3.4L 3.5L 3.8L 3.9L 3.8L SC V8 5.3LChevrolet/GMUPLANDER03-084 SP F/4WDV6 3.5L 3.9LChevrolet/GMVENTURE APV99-054 SP FWDV6 3.4LOldsmobile88 ROYALE97-994 SP FWDV6 3.8L 3.8L SCOldsmobileAURORA01-034 SP F/4WDV6 3.5LOldsmobileINTRIGUE98-024 SP F/4WDV6 3.5L 3.8L V8 4.5LOldsmobileSILHOUETTE99-044 SP F/4WDV6 3.4LPontiacAZTEK01-054 SP F/4WDV6 3.4LPontiacBONNEVILLE97-054 SP F/4WDV6 3.8L 4.6LPontiacG606-094 SP FWDV6 3.9LPontiacGRAND PRIX97-084 SP F/4WDV6 3.1L 3.8L V8 5.3LPontiacMONTANA / SV699-084 SP F/4WDV6 3.5L 3.9LPontiacTRANS SPORT99-044 SP F/4WDV6 3.4LSaturnRELAY05-074 SP F/4WDV6 3.5L 3.9LVolvoS8099-064 SP FWDL6 2.9L How to repair this transmission (Videos)Teardown Inspection with code P1811 Transmission Teardown Inspection4T65E-HD (Part 1)4T65E-HD (Part 2)4T65E-HD (Part 3)4T65E-HD (Part 4)4T65E-HD (Part 5)4T65E-HD (Part 6)4T65E-HD (Part 7)4T65E HD Part 84T65E HD Part 9 Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comTransTec Manual 4T65epdfwww.at-manuals.comScheme 4T65ewebwww.at-manuals.comCheck Balls 4T65ewebwww.at-manuals.com4T60E SolenoidspdfSonnaxValve Body Layout 4T65-EpdfSonnaxVacuum test 4T65-E

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATFWD23011,76,5Dexron 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?BrandModelYearTypeEngineBuickSKYLARK974 SP FWDL4 2.4LChevrolet/GMCAVALIER95-054 SP FWDL4 2.2L 2.3L 2.4LChevrolet/GMLACETTI06-084 SP FWDL4 1.5L 1.6LDaewooNEXIA00-034 SP FWDL4 1.5LDaewooNUBIRA-200-044 SP FWDL4 1.5L 1.6L 1.8L 2.0LOldsmobileALERO99-044 SP F/4WDL4 2.2L 2.4LOldsmobileCUTLASS97-994 SP FWDV6 3.1LPontiacGRAND AM99-054 SP FWDL4 2.2L 2.4LPontiacSUNFIRE95-054 SP F/4WDL4 2.2L 2.4L How to repair this transmission (Videos)4T40E TeardownTransmission - Teardown Inspection

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATRWD100016,28Mercon 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?BrandModelYearTypeEngineFordECONOLINE 1501/98-044 SP RWDV8 5.4LFordECONOLINE 250/250 SUPER DUTY1/98-044 SP RWDV8 5.4L 7.3L DIESEL V10 6.8LFordECONOLINE 350/350 SUPER DUTY1/98-054 SP RWDV8 5.4L 7.3L DIESEL V10 6.8LFordEXCURSION00-054 SP R/4WDV8 5.4L 7.3L DIESEL V10 6.8LFordEXPEDITION1/98-024 SP R/4WDV8 5.4LFordF-150 /F-2501/98-074 SP R/4WDV8 5.4L 7.3L DIESEL V10 6.8LFordF-350/350 SUPER DUTY99-044 SP R/4WDV8 5.4L 7.3L DIESEL V10 6.8LFordF-450/550 SUPER DUTY3/98-044 SP R/4WDV8 7.3L DIESEL V10 6.8LLincolnBLACKWOOD24 SP RWDV8 5.4LLincolnNAVIGATOR1/98-044 SP R/4WDV8 5.4L How to repair this transmission (Videos)Teardown Inspection, No 2-3 UpShift4R100 Teardown4R100 rebuild Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comScheme 4R100webSonnax6 Key Features to Understand in Ford E4OD, 4R100 & 5R110W

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATFWD2406,94LT 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?BrandModelYearTypeEngineBuickEXCELLE03-094 SP FWDL4 1.8LChevrolet/GMEPICA05-124 SP FWDL4 2.0LChevrolet/GMOPTRA03-124 SP FWDL4 1.8LChevrolet/GMORLANDO10-114 SP FWDL4 1.8L 2.0L DIESELDaewooLACETTI02-114 SP FWDL4 1.6L 1.8L 2.0LDaewooLEGANZA00-034 SP FWDL4 1.8L 2.0L 2.2LDaewooMAGNUS00-034 SP FWDL4 2.0L V6 2.5LDaewooREZZO00-084 SP FWDL4 2.0LSuzukiFORENZA04-084 SP FWDL4 2.0LSuzukiRENO04-084 SP FWDL4 2.0LSuzukiVERONA04-064 SP FWDL6 2.5L How to repair this transmission (Videos)zf 4hp16 picturesZf4hp16 valve bodyZf4hp16 valve body2 Instruction manuals and useful linksLink typeSourceDescriptionpdfwww.at-manuals.comScheme

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 gearsTransmission TypeDriveTorque (Nm)ATF (full capacity) LATF (change) LATF type4ATRWD/4WD48810,85Dexron 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?BrandModelYearTypeEngineChevrolet/GMC/K PICK-UP 1500-2500-3500(95)95-974 SP R/4WDV6 4.3L V8 4.8L 5.0L 5.3L 5.7L 6.0LChevrolet/GMVAN FULL SIZE 1500-250095-114 SP RWDV6 4.3L V8 4.8L 5.0L 5.3L 5.7L 6.5L DIESELChevrolet/GMVAN FULL SIZE 350095-994 SP RWDV6 4.3L How to repair this transmission (Videos)Gear Train Removal and InspectionValvebody and Pump DisassemblyReverse Input Drum and Input Clutch AssembleReassembly of Pump and Gear Train Instruction manuals and useful linksLink typeSourceDescriptionwebwww.at-manuals.comTransmission scheme 4L60webwww.at-manuals.comSolenoids 4L60Ewebwww.at-manuals.com4L60/4L65E componentspdfwww.at-manuals.comScheme 4L60pdfwww.at-manuals.comRebuild manual 4L60epdfwww.at-manuals.comRepair manual 4L60epdfwww.at-manuals.comTurning a 4L60E into a Manually Shifted TranspdfSonnaxVacuum test 4L60-E, 4L65-E, 4L70-EpdfSonnaxRecognize & Repair Solenoid Accumulators in Late-Model Valve BodieswebSonnaxBUILD THE KILLER 4L60-EwebSonnax4L60-E Valve Body Identification GuidevideoSonnaxGuide to a Sonnax 4L60/E Level 3 Performance Build