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aw55-50/sn series

1. de a Eau EP E ed es 95 EARLFVALVE BODY KEEN 102 i LATE VALUE BOD VID Bb RES OE EE EE OE ES 109 LATE VALVE BODY C lt N EE OE issues beta 116 TRANSAXLE FINAL ASSE MBLY cccccccccccccccccscsccccscccccccccccccccscccsccccccccccccccccccccscsccccccccccccccccccccscccccccescccccccccccccccess 123 VALVE BODY AND SOLENOID ID FOR SERVICE ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccceccccccoccccccecccecs 137 OPE RATING MODEG cccccccccccccccccccccccccccccccccccccccccccccccccccscccsccccccccccccccccccccccccescccccccccccccscccsccccccccccccccccccccscccccccecocecocs 151 d BEARING AND RACE LOCATIONS AND SPE CLF ICATTIONG ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccoccccecs 158 FASTENER TIGHTENING SPE CLP ICATTIONG cccccccccccccccccccccccsccccccccccccccccccccccccccccccccccccccecccccccccccccecccccccccccocecs 160 PRESSURE PORT LOCATIONS AND SPE CLF ICATIONG cccccccccccccccccccccccccccccccccccccccccecccccccccccccccccccccccccccccccccces 162 Copyright ATSG 2011 RE 2 e ATSG Technical Service Information SATURN GM SAAB VOLVO NISSAN AF23 33 5 AWS5 50 51SN RESF22A CUT AWAY VIEW INTERNAL COMPONENT LOCATIONS LOW CLUTCH SPRAG F2 LOW REVERSE BRAKE B3 SECOND BRAKE B2 dttnnl ELE EE RAT Ni HELE j FORWARD CLUTCH C1 H
2. CHECK VALVE SPRING ID WHITE REVERSE INHIBIT CHECK BALL INNER BUSHING REVERSE INHIBIT CHECK BALL REVERSE INHIBIT CHECK BALL OUTER BUSHING LOCK UP CONTROL VALVE LOCK UP CONTROL VALVE PLUNGER LOCK UP CONTROL VALVE SPRING ID YELLOW LOCK UP CONTROL VALVE SLEEVE BORE PLUG RETAINER 1 3 2 X 5 X 21 2 mm Copyright 2011 ATSG PGATSG PRESSURE RELIEF VALVE SPRING 4 WIRE DIAMETER 050 OUTSIDE DIAMETER 370 OVERALL LENGTH 1 128 COILS 5 COLOR ID NONE SOLENOID RELAY VALVE SPRING 25 WIRE DIAMETER 019 OUTSIDE DIAMETER 235 OVERALL LENGTH 800 COILS 9 COLOR ID ORANGE U1 SHIFT VALVE SPRING 40 WIRE DIAMETER 032 OUTSIDE DIAMETER 396 OVERALL LENGTH 1 044 COILS 7 COLOR ID LT GREEN LOCK UP RELAY VALVE SPRING 51 WIRE DIAMETER 022 OUTSIDE DIAMETER 231 OVERALL LENGTH 0 927 COILS 12 COLOR ID RED SHIFT PRESSURE CONTROL VALVE SPRING 63 WIRE DIAMETER 025 OUTSIDE DIAMETER 229 OVERALL LENGTH 0 620 COILS 12 COLOR ID WHITE B2 CONTROL VALVE SPRING 79 WIRE DIAMETER 032 OUTSIDE DIAMETER 382 OVERALL LENGTH 1 339 COILS 9 COLOR ID NONE B5 CONTROL VALVE SPRING 53 WIRE DIAMETER 027 OUTSIDE DIAMETER 315 OVERALL LENGTH 650 COILS 4 5 COLOR ID LT GREEN Technical Service Information CONTROL VALVE BODY ASSEMBLY SPRING SPECIFICATIONS LATE VALVE BODY ID STAMP 8 SOLENOID MODULATOR VALVE SPRING 10 WIRE DIAMETER 043 OUT
3. 25 FRONT INTERNAL GEAR AND LOW CLUTCH SPRAG F2 ASSEMBLY 516 LOW AND REVERSE BRAKE B3 LINED PLATE 4 REQUIRED 510 LOW AND REVERSE BRAKE B3 PISTON INNER SEAL 517 LOW AND REVERSE BRAKE B3 STEEL PLATE 3 REQUIRED 511 LOW AND REVERSE BRAKE B3 PISTON ASSEMBLY 518 LOW AND REVERSE BRAKE B3 BACKING PLATE RETAINING SNAP RING 512 LOW AND REVERSE BRAKE B3 PISTON OUTER SEAL 519 FRONT INTERNAL GEAR THRUST BEARING ASSEMBLY 513 LOW AND REVERSE BRAKE B3 PISTON RETURN SPRING ASSEMBLY 527 FRONT INTERNAL GEAR FLANGE 514 LOW AND REVERSE BRAKE B3 PISTON RETURN SPRING ASSEMBLY RETAINING SNAP RING 528 FRONT INTERNAL GEAR FLANGE RETAINING SNAP RING 515 LOW AND REVERSE BRAKE B3 PACKING PLATE 529 FRONT INTERNAL GEAR THRUST BEARING ASSEMBLY 2 REQUIRED 530 FRONT INTERNAL GEAR THRUST BEARING ASSEMBLY RACE Copyright 2011 ATSG Figure 142 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS Low and Reverse Brake B3 Front Internal Gear and Low Clutch Sprag F2 Assembly 1 Disassemble the Low and Reverse Brake B3 Front Internal Gear and Low Clutch Sprag F2 Assembly using the diagram in Figure 142 as a guide NOTE The Low Clutch Sprag F2 assembly does not come apart If wear is indicated it must be replaced as an assembly 2 Clean all Low and Reverse Brake B3 Front Internal Gear and Low Clutch Sprag F2 Assembly parts thoroughly and dry with compressed air 3 Inspect all Low and Reverse Brake B3 Front
4. 128 129 130 131 132 133 134 135 136 137 FRONT CONTROL VALVE BODY SPACER PLATE TO MIDDLE CONTROL VALVE BODY GASKET MIDDLE CONTROL VALVE BODY ASSEMBLY MIDDLE CONTROL VALVE BODY ASSEMBLY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND BONDED GASKETS REAR CONTROL VALVE BODY ASSEMBLY REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY ASSEMBLY GASKET REAR CONTROL VALVE BODY SPACER PLATE REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKET NO 2 REAR CONTROL VALVE BODY ASSEMBLY CONTROL VALVE BODY BOLT M5 X 0 8 X 76 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 40 mm 1 REQUIRED CONTROL VALVE BODY ASSEMBLY PRESSURE TEST PORT BOLT M6 X 1 0 X 12 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 35 mm 2 REQUIRED MANUAL VALVE LINK MANUAL VALVE MANUAL VALVE LINK RETAINING CLIP TCC PRESSURE CONTROL SOLENOID SLU CONNECTOR BLACK SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR GREEN Figure 181 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright 2009 ATSG e ATSG Technical Service Information FRONT CONTROL VALVE BODY ga 93535353 33333353 GE 83333333 52925297 SASSER POT ENS BES De LENS le VW 7 Y U N V N a NE 7 i SN Y 9 S 10 M MOS EP a 14 LDV i N gt 16 S
5. FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEARIN cccccccccccccccccccccccccccccccccccccccccccccccccces 41 OIL PUMPASSEMBLY 2ND COAST BRAKE B1 2ND BRAKE B2 ASSEMBL Y eee eee eene 42 2ND COAST BRAKE B1 2ND BRAKE B2 HUB 2ND BRAKE SPRAG F1 ASSEM BLY 56 2ND BRAKE SPRAG F1 ROTATION vvsssessenessessensssessenessessenensensssensensssensensssensenensensssensenessensesessensesensensssensenes 57 FORWARD C1 AND DIRECT C2 CLUTCH ASSEMBILE EE 59 REAR COVER 1 2 REVERSE BRAKE B5 HOUSINGASSEMBLY sesse ee esse ee eee eee se rere ene ee ees sesse ee ees 63 4 5 CLUTCH C3 ASSEMBLY ENEE 69 L R BRAKE B3 FRONT INTERNAL GEAR AND LOW CLUTCH SPRAG F2 eee eee eee eene 72 LOW CLUTCH SPRAG F2 KU E ENT N sis es bs D D 74 SRD GEAR BAND B4 SERVO ASSEMBLY 1ccccsssseccsscssseccccssecccccnscccccccssnsccccscsccccccescccccccssccccsessccccsessccccceesess 75 1 2 REVERSE CARRIER GEAR ASS E MBL ccccccccccccccccccccccccccccccccccccccccccccccccccecccccceccccccccccccccceccccececccccccs 76 i FRONT PLANET CARRIER AND SUN GEAR ASSE MBL Y cccccccccccccccccccccccccccccccccccccccccccccccccccccccccscccccces 17 CONTROL VALVE BODYASSE M B L cccccccccccccccccccccccccccccccccccccccccceccccccecccccccccccccoccccccecccccceccccccoceccccocccecs 79 CONTROL VALVE BODYASSEMBLY EARLYAND LATE DIFFERENCES EARLYVALVE BODY ID NONE iss sides se dies iS ies uso de oss eL
6. TCM Black 38 Way Connector Shift Red Solenoid 3 EN Lt Green 14 Orange Black Shift R Solenoid 4 ed Yellow Black k Red White a Purple Red Shift Lt Blue Purple Solenoid 5 Lamps On Off N C KI Orange White 12 Purple Black White Line Pressure Purple White Black White Grnd Solenoid SLT Orange White PWM E Orange White Pos 36 mum E B Red White Grnd mm j i Solenoid SLS 26 White ry Pink White Pos E og Dk Blue EJ Lt Green Grnd TCC Dk Green mu Dk Blue Pos Solenoid SLU PWM mai Orange Black Lo 31 Transmission 2 Tan White T Tan White Hi Fluid Temp Starter Relay Purple Lo Underhood 1 23 Fuse Block TEER Z SO Sa eo S le S zigi del Seil Dk Blue White Lo N ue lie LO mE 22 nm TUC Pink Pink Transaxle Yellow 4 R ange Switch 6 Tan White Tan White Yellow Yellow 6 Gray Gray 7 White White ry Copyright 2011 ATSG Figure 16 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TRANSAXLE CASE 14 WAY CONNECTOR IDENTIFICATION Terminal Component Numbers Ohms Resistance 11 16 Ohms 20 68 F 11 16 Ohms 20 68 F 11 16 Ohms 20 68 F 5 0 5 6 Ohms 20 68 F 5 0 5 6 Ohms 20 68 E In
7. Torque Specification M6 x 1 0 x 14 5 mm Pump Cover Bolt 231 13 required 12 N m 106 in Ib Copyright 2011 ATSG Figure 114 PAATSG Technical Service Information SECOND COAST BRAKE 87 SECOND BRAKE 82 HUB AND SECOND BRAKE SPRAC F7 ASSEMBLY 505 506 502 500 SECOND COAST BRAKE B1 HUB SPRAG INNER RACE ASSEMBLY 501 SECOND COAST BRAKE B1 THRUST WASHER 502 SECOND BRAKE SPRAG F1 END BEARING 2 REQUIRED 503 SECOND BRAKE SPRAG F1 ASSEMBLY 505 SECOND BRAKE SPRAG F1 OUTER RACE AND CLUTCH HUB ASSEMBLY 506 SECOND BRAKE SPRAG F1 OUTER RACE AND CLUTCH HUB ASSEMBLY THRUST WASHER Copyright 2011 ATSG Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information EE 7 Install the Second Coast Brake B1 Hub onto the O e A SEM Sprag Assembly using a clockwise twisting 1 Disassemble the Second Coast Brake Bl motion as shown in Figure 117 Second Brake 2 Hub and Second Brake Sprag 8 Check for proper Sprag rotation The Second F1 Assembly using the diagram in Figure 115 as Coast Brake B1 Hub Sprag Inner Race must a guide Freewheel Clockwise and Lock Counter 2 Clean all Second Coast Brake B1 Second Brake Clockwise as indicated in Figure 118 B2 Hub and Second Brake Sprag F1 parts with solvent and dry with compressed air 3 Inspect the Sprag the Inner and Outer Race for wear and replace as necessary 4 Coat the Second Brake Sprag F1 Assembly
8. Invalid Torque Delivered Signal from ECM via CAN Invalid Torque Reduction request from ECM via CAN Invalid Engine Torque Signal Circuit from ECM via CAN Invalid Pedal Position Signal Circuit from ECM via CAN Invalid Engine Coolant Signal Circuit from ECM via CAN Transmission fluid over 212 F or Calculated Fluid life at 0 Copyright 2011 ATSG Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP QO ARTS SAFETY PRECAUTIONS Service information provided in this manual by ATSG is intended for use by professionally qualified technicians Attempting repairs or service without the appropriate training tools and equipment could cause injury to you or to others The service procedures we recommend and describe in this manual are effective methods of performing service and repair on this transmission Some of the procedures require the use of special tools that are designed for specific purposes This manual contains CAUTIONS that you must observe carefully in order to reduce the risk of injury to yourself or to others This manual also contains NOTES that must be carefully followed in order to avoid improper service that may damage the vehicle tools and or equipment aan 2011 ATSG Figure 21 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information TRANSANLE DISASSEMBLY EXTERNAL COMPONENTS 1 The transaxle should be cleaned on the outside to remove dirt or grease prior to disassembly 2 This tran
9. PRESSURE REGULATOR VALVE SPRING 30 WIRE DIAMETER 047 OUTSIDE DIAMETER 525 OVERALL LENGTH 1 890 COILS 12 COLOR ID PURPLE B4 BAND RELEASE VALVE SPRING 41 WIRE DIAMETER 027 OUTSIDE DIAMETER 354 OVERALL LENGTH 0 902 COILS 8 COLOR ID BLUE SECONDARY REGULATOR VALVE SPRING 58 WIRE DIAMETER 038 OUTSIDE DIAMETER 382 OVERALL LENGTH 1 866 COILS 16 COLOR ID NONE M2 SHIFT VALVE SPRING 68 WIRE DIAMETER 027 OUTSIDE DIAMETER 322 OVERALL LENGTH 1 044 COILS 9 COLOR ID LT BLUE TCC CHECK VALVE SPRING 82 WIRE DIAMETER 016 OUTSIDE DIAMETER 205 OVERALL LENGTH 0 468 COILS 7 COLOR ID WHITE NEUTRAL RELAY VALVE SPRING 14 WIRE DIAMETER 026 OUTSIDE DIAMETER 324 OVERALL LENGTH 1 021 COILS 9 COLOR ID LT GREEN U2 SHIFT VALVE SPRING 34 WIRE DIAMETER 032 OUTSIDE DIAMETER 394 OVERALL LENGTH 1 014 COILS 7 COLOR ID LT GREEN COOLER BYPASS VALVE SPRING 45 WIRE DIAMETER 042 OUTSIDE DIAMETER 471 OVERALL LENGTH 680 COILS 6 COLOR ID NONE SLT ACCUMULATOR SPRING OUTER 60 WIRE DIAMETER 088 OUTSIDE DIAMETER 645 OVERALL LENGTH 1 555 COILS 9 COLOR ID ORANGE SHIFT PRESSURE RELAY VALVE SPRING 70 WIRE DIAMETER 033 OUTSIDE DIAMETER 399 OVERALL LENGTH 1 009 COILS 7 COLOR ID LT GREEN LOCK UP CONTROL VALVE SPRING 88 WIRE DIAMETER 027 OUTSIDE DIAMETER 222 OVERALL LENGTH 0 813 COILS 11 COLOR ID YELL
10. Published September 2011 INTRODUCTION SGATSG SATURN GM SAAB VOLVO NISSAN AF23 33 5 AW55 50 5 ISN RESF22A The AF23 33 5 is a fully automatic five speed electrically controlled front wheel drive transmission This transmission 1s currently used by many different vehicle manufacturers among them are GM Infiniti Nissan Saab Saturn Suzuki and Volvo In the GM Saturn and Suzuki vehicles the transmission is known as the AF23 33 5 In Saab vehicles it s designated FA 57 Nissan and Infiniti call it the RESF22A and in a Volvo it s known as the AW55 50 51SN This transmission contains three planetary gear sets three driving friction elements five holding friction elements one of which is a servo applied band two sprags and a torque converter which contains a clutch assembly for increased fuel efficiency The three planetary gear sets provide five forward speeds and one reverse speed Gear ratio change is fully automatic and controlled through the Transmission Control Module TCM The TCM monitors and receives inputs from various electronic sensors then uses the information to control shift timing clutch apply control line pressure control and torque converter clutch application This manual will contain overhaul information pertaining to the AF23 33 5 AW55 50 51SN and RESF22A transmission Portions of materials contained herein have been reprinted under license from General Motors Corporation Service amp Parts Op
11. Referto Figure 18 and Figure 19 for DTC definitions OUTPUT INPUT SENSOR LOCATIONS Output Shaft Speed OSS Sensor PARKING GEAR LOW SPEED HIGH SPEED 0 am gt E 2 A E O TYPICAL SENSOR SIGNAL Input Shaft Speed ISS Sensor FORWARD AND DIRECT CLUTCH HOUSING WITH INPUT SHAFT Output Shaft Speed OSS Sensor Input Shaft Speed ISS Sensor Y S gt i D 4 Copyright O 2011 ATSG Figure 7 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS ELECTRICAL COMPONENTS Cont d Park Neutral Position Switch The Park Neutral Position Switch assembly is a sliding contact switch attached to the manual shift detent lever assembly on the outside of transaxle as shown in Figure 8 The four inputs to the TCM from the P N switch indicate which position has been selected by the manual selector lever This information is used for engine controls as well as determining the transaxle shift patterns The state of each input is available for display on the scan tool The four input parameters shown in Figure 9 are Mode A Mode B Mode C and Mode PA Technical Service Information The Park Neutral Position Switch assembly 1s also responsible for allowing the engine to be started in Park or Neutral only and no other selector position This switch is also responsible for illuminating the Back Up lamps when Reverse is selected as shown in Figure 9 If the TCM detects an improper signal from the Park
12. 52 Carefully install the Second Coast Brake B1 Piston Assembly into the pump assembly using a twisting motion as shown in Figure 110 53 Install the Second Coast Brake B1 Piston Return Spring Assembly aligning the springs into the piston as shown in Figure 110 54 Using SST J 23327 and J 41236 or other similar spring compressor tool compress the Second Coast Brake B1 Piston Return Spring Assembly and install the Piston Return Spring Retaining snap Ring into the pump body assembly using a pair of snap ring pliers or a small screwdriver as shown in Figure 110 55 Make certain the retaining snap ring 1s fully seated into the snap ring groove in the pump body assembly Note frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 56 Install the Second Coast Brake B1 clutch plates starting with a Steel Plate and alternating lined plates and steel plates ending with a lined plate as shown in Figure 111 57 Install the Second Coast Brake B1 Backing Plate as shown in Figure 111 58 Using SST J 23327 Spring Compressor or other similar tool compress the Second Brake B2 spring 59 Using SST J 28585 or a pair of snap ring pliers install the Second Coast Brake B1 Backing Plate Retaining snap ring making sure the snap ring 1s fully seated as shown in Figure 111 60 Using SST J 45166 and J 45200 or other adequate dial indicator set the dial indicator base onto the pump body assemb
13. B4 Servo Assembly parts thoroughly and dry with compressed air 3 Inspect all servo parts and replace as necessary 4 Reassemble the Third Gear Band B4 Servo Piston Assembly using the diagram in Figure 147 as a guide 5 Install a new O ring seal onto the servo piston and two new O ring seals onto the piston cover as shown in Figure 147 Coat the three O ring seals with a small amount of Trans Jel 6 During final assembly 1t will be necessary to check the servo piston travel Servo piston travel specification 1s provided in the Servo Assembly Specifications chart shown in Figure 148 If servo piston travel 1s not within specification select a different servo pin from the chart in Figure 148 Servo Assembly Specifications Third Gear Band B4 Specification Metric English Copyright O 2011 ATSG Figure 148 AUTOMATIC TRANSMISSION SERVICE GROUP PGATSG 1 2 REVERSE CARRIER GEAR ASSEMBLY 1 2 REVERSE CARRIER THRUST WASHER 2 REQUIRED 1 2 REVERSE PLANETARY CARRIER GEAR ASSEMBLY 1 2 REVERSE CARRIER GEAR FRONT THRUST BEARING ASSEMBLY 1 2 REVERSE INTERNAL GEAR 1 2 REVERSE INTERNAL GEAR REAR THRUST BEARING ASSEMBLY 1 2 REVERSE INTERNAL GEAR SHIM SELECTIVE Copyright 2011 ATSG Figure 149 Technical Service Information 1 2 Reverse Carrier Gear Assembly l Disassemble the 1 2 Reverse Carrier Gear Assembly using the diagram in Figure 149 as a guide 2 Clean all 1 2 Reverse Carrier Gear Assembly
14. CLUTCH DRUM FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY HOUSING ASSEMBLY Copyright O 2011 ATSG Copyright O 2011 ATSG Figure 123 Figure 124 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Forward CI and Direct C2 Clutch Assembly Cont d 16 Install the Direct Clutch C2 Backing Plate Retaining Snap Ring into the drum as shown in Figure 123 17 Make sure the snap ring is fully seated in the snap ring groove Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 18 Starting with a Steel Plate and alternating Steel Plates and Lined Plates install the Forward Clutch C1 Steel and Lined Plates into the drum as shown in Figure 124 19 Install the Forward Clutch C1 Backing Plate into the drum as shown in Figure 124 20 Install the Forward Clutch C1 Backing Plate Retaining Snap Ring into the drum as shown in Figure 124 21 Make sure the snap ring 1s fully seated in the snap ring groove Technical Service Information 22 Install the Forward C1 and Direct C2 Thrust Bearing Race and Thrust Bearing into the drum and retain with a small amount of Trans Jel then install a new Turbine Shaft Seal Ring and coat with a small amount of Trans Jel as shown in Figure 125 23 Set the Forward C1 and Direct C2 Clutch Drum into the 1 2 Reverse Brake Housing then using SST J 45166 and J 45200 or other adequate dial indicator attach the base onto the housing bo
15. Copyright O 2011 ATSG Copyright 2011 ATSG Figure 155 Figure 156 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 7 Remove the front control valve body assembly the 8 To avoid losing small parts flip the front control front control valve body spacer plate and gaskets valve body assembly so the gaskets and spacer together as an assembly by holding the front plate are facing upward and lay on the work area for control valve body spacer plate against the front further disassembly as shown in Figure 157 control valve body while lifting gently away from 9 Remove the shift solenoid filters and the the middle control valve body assembly accumulator check valves from the middle control VQ Vii ZL N CO MN Wid Au ANG NG SC ui Ma A valve body as shown in Figure 158 10 Remove the control valve body bolt from the ELIP VALVE BODY OVER middle control valve body using an 8 mm socket as SO GASKETS AND PLATE shown in Figure 158 ARE FACING UPWARD Cont d on page 82 FRONT CONTROL VALVE BODY ASSEMBLY FRONT CONTROL VALVE BODY SPACER PLATE TO 18 SOLENOID OIL FILTER S2 S3 S4 FRONT CONTROL VALVE BODY GASKET 19 SOLENOID OIL FILTER S1 S5 FRONT CONTROL VALVE BODY SPACER PLATE 20 ACCUMULATOR CHECK VALVE FRONT CONTROL VALVE BODY TO MIDDLE CONTROL VALVE BODY GASKET 104 CONTROL VALVE BODY BOLT MIDDLE CON
16. Ifthe accelerator pedal position angle is less than 3 and the vehicle speed is increasing Mode shift points will be raised to a higher speed to provide for engine braking A downshift may be noticed in some vehicles when the brake pedal is depressed under this condition High Altitude Ifthe barometric pressure is less than 12 76 PSI absolute then the control module will Mode raise shift points slightly to compensate for reduced engine power Traffic If the vehicle stops and starts with less than 10 accelerator angle then 1st gear will be Jam inhibited A rolling 2nd gear start is commanded in an effort to increase fuel economy Mode and make shifting less busy Traffic Jam Mode is turned off with the accelerator angle greater than 30 or ifthe vehicle slows to less than 1 MPH or exceeds 18 MPH 152 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES OPERATING MODES VOLVO VEHICLE SHIFT MODES Economy The control module provides earliest possible up shifts and lock up for best fuel Mode economy under normal driving conditions Oil pressures are adjusted electronically to provide for smooth shifting and garage shift engagements The control module changes from Economy to Sport Mode if the accelerator is Sport depressed quickly and the vehicle exceeds 31 MPH In Sport Mode shift points are Mode raised to provide the best performance and downshifting occurs at a lower engine RPM Economy Mode
17. Install the transmission fluid filter retaining bolt M6 x 1 0 x 16 7 mm as shown in Figure 241 75 Torque the transmission fluid filter retaining bolt to 5 Nm 44 in Ib as shown in Figure 241 76 Apply a 3 mm 1 8 in bead of sealant GM P N 89020326 or equivalent to the inside of the bolt holes on the mating surface of the torque converter housing as shown in Figure 242 77 Apply threadlocker GM P N 12345382 or equivalent to each of the torque converter housing bolts 78 Install the eleven M8 x 1 25 x 30 mm bolts 4 and hand tighten as shown in Figure 243 79 Install the two M8 x 1 25 x 30 mm bolt studs 3 and hand tighten as shwon in Figure 243 Copyright 2011 ATSG Figure 240 R TORQUE BOLT TO 5 Nm 44 in lb TL q 255 Copyright 2011 ATSG Figure 241 Technical Service Information 80 Install the two M8 x 1 25 x 35 mm bolts 6 and hand tighten as shown in Figure 243 81 Install the one M3 x 1 25 x 45 mm bolt 7 and hand tighten as shown in Figure 243 82 Install the one M8 x 1 25 x 30 mm TORX 40 bolt 8 and hand tighten as shown in Figure 243 Cont d on page 132 Figure 243 AUTOMATIC TRANSMISSION SERVICE GROUP 151 e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 83 Torque the seventeen torque converter housing bolts to 29 Nm 21 Ib ft according to the sequence shown in Figure 244 84 Install SST J 45053 or similar pump removal installing tool ont
18. Permission predetermined minimal vehicle speed The TCM has an electrical fail safe mode This mode makes it possible to operate even if Fail Safe there is a malfunction in a main electronic control input or output signal circuit Mode In fail safe mode the driving condition is determined according to the area of the malfunction and line pressure is set at maximum See Nissan fail safe charts to follow Diagnosis and repair 1s made according to the type of fault code stored UP DOWN SHIFT LEARNING CONTROL This control learns the pressure to each clutch or brake to reduce shift shock for all up down and coast down shifting N D SHIFT CONTROL This control improves N D shift quality by controlling the line pressure solenoid on forward engagements including the Lrange N D SHIFT LEARNING CONTROL This control learns the forward clutch piston stroke and apply pressure by monitoring the forward clutch engagement time based on a rotational change rate N R SHIFT CONTROL This control improves N R shift quality by controlling the shift pressure solenoid during reverse engagements N R SHIFT LEARNING CONTROL This control learns the direct clutch piston stroke and apply pressure by monitoring the direct clutch engagement time based on a rotational change rate TORQUE REDUCTION CONTROL This control improves shift quality by sending a torque reduction request signal form the TCM to the ECM to cut engine torque increase at N D N
19. The S1 and S4 solenoids are normally open while the S3 and S5 solenoids are normally closed for all versions The 2 solenoid however may be either normally open or normally closed dependant upon the vehicle manufacturer A GM Saab or Saturn valve body will use a normally open S2 solenoid that can be identified by the raised domed top as depicted in Figure 261 The Nissan Volvo valve bodies use a normally closed S2 solenoid that can be identified by the flat top with 4 raised lines radiating from the hole in the center of the solenoid as shown in Figure 262 Nissan and Volvo vehicles have the S2 solenoid firing sequence opposite to the GM Saab Saturn vehicles as indicated in Figure 263 The SLU solenoid also referred to as the lock up or solenoid 15 located at the top ofthe valve body with a black connector turned upwards This is a PWM type solenoid that typically measures 5 0 5 6 ohms resistance and has remained the same through all versions The SLS Shift Pressure Solenoid and the SLT Line Pressure Solenoid have been redesigned twice for a total of 3 versions of each solenoid Both of these solenoids are of the PWM type and will typically measure 5 0 5 6 ohms resistance The SLS and SLT solenoids are retained to the valve body by the same retaining bracket There are three different versions of this bracket The original version proved to be a bit weak so as a result the second version is basically the same as the first design in app
20. While holding the separator plate and gaskets tothe 55 Install and hand tighten the seven control valve front control valve body flip the valve body over body attaching bolts as shown in Figure 174 and align the bolt holes in the front control valve Using a torque wrench and an 8 mm socket tighten body with the bolt holes in the middle control valve all sixteen control valve body attaching bolts body and set valve body down onto middle control evenly from the center out and torque to 7 N m 62 valve body as shown in Figure 174 in b as shown in Figure 175 Cont d on page 93 TORQUE CONTROL VALVE BODY ATTACHING BOLTS TO 7N m 62 n lb N REZ NN X 7 AN 104 CONTROL VALVE BODY BOLT M5 X 0 8 X 50 mm 2 Required 112 CONTROL VALVE BODY BOLT M5 X 0 8 X 20 mm 4 Required 113 CONTROL VALVE BODY BOLT M5 X 0 8 X 16 mm 2 Required 114 FRONT CONTROL VALVE BODY ASSEMBLY 119 FRONT CONTROL VALVE BODY SEPARATOR PLATE 121 MIDDLE CONTROL VALVE BODY ASSEMBLY Copyright O 2011 ATSG Copyright O 2011 ATSG Figure 174 Figure 175 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 56 Install new o rings on each of the five shift solenoids Coat the o rings with a small amount of ATF or Trans Jel then install each solenoid into the front control valve body as shown in Figure 176 100 1 2 2 3 REVERSE SHIFT SOLENOID S3 CONNE
21. have provided you with a chart in Figure 15 that identifies the individual terminals in the 14 way transaxle case connector and the vehicle external harness connector color of the wires and circuit function A complete transaxle wire schematic from transaxle to the TCM is provided in Figure 16 and a resistance chart for internal transaxle electrical components is shown in Figure 17 TRANSAXLE CASE 14 WAY CONNECTOR IDENTIFICATION Pin Circuit No Wire Color Number Circuit Function Orange Black Transaxle Fluid Temp TFT Lo signal to TCM Red White Shift Pressure Control Solenoid SLS ground signal from TCM TCC Control Solenoid SLU ground signal from TCM Black White Line Pressure Control Solenoid SLT ground signal from TCM Shift Solenoid 4 S4 voltage signal from TCM Shift Solenoid 2 S2 voltage signal from TCM 9 j 6 7 9 Transaxle Fluid Temp TFT Hi signal to TCM White Shift Pressure Control Solenoid SLS voltage signal from TCM 6 5 7 k 74 72 7 7 7 73 Purple Whi Shift Solenoid I SI voltage signal from TCM Transaxle Case Connector Vehicle Harness Connector Face View Face View Copyright 2011 ATSG Figure 15 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information SATURN VUE AF23 33 5 ELECTRICAL COMPONENT WIRE SCHEMATIC Shift Orange Black Solenoid 1 On Off N O Transaxle Case On Off N 0 14 Way Connector Shift Red White Solenoid 2
22. shown in Figure 122 11 Using SST J 25024 A J 45186 J 21420 and J 23327 or similar spring compression tool and press such as an arbor press compress the Direct Clutch C2 Piston Return Spring and install the Direct Clutch C2 Piston Return Spring Retaining Snap Ring using a pair of snap ring pliers as shown in Figure 122 12 Make sure the snap ring is fully seated in the snap ring groove Cont d on page 61 e ATSG Technical Service Information Forward CI and Direct C2 Clutch Assembly Cont d Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 13 Install the Direct Clutch C2 Apply Plate into the drum as shown in Figure 123 14 Starting with a Steel Plate and alternating Steel Plates and Lined Plates install the Direct Clutch C2 Steel and Lined Plates into the drum as shown in Figure 123 15 Install the Direct Clutch C2 Backing Plate into the drum as shown in Figure 123 Cont d on page 62 DIRECT CLUTCH C2 BACKING PLATE RETAINING FORWARD CLUTCH C1 BACKING PLATE SNAP RING RETAINING SNAP RING DIRECT CLUTCH C2 BACKING PLATE SELECTIVE FORWARD CLUTCH C1 BACKING PLATE SELECTIVE DIRECT CLUTCH C2 LINED PLATE 4 REQUIRED FORWARD CLUTCH C1 LINED PLATE 4 REQUIRED DIRECT CLUTCH C2 STEEL PLATE 4 REQUIRED FORWARD CLUTCH C1 STEEL PLATE 4 REQUIRED DIRECT CLUTCH C2 APPLY CUSHION PLATE FORWARD C1 AND DIRECT C2
23. 1 0 X 14 3 REQUIRED Copyright O 2011 ATSG Figure 69 Technical Service Information 17 Coat the inside of the seal with a small amount of Trans Jel amp and set the torque converter housing assembly aside for final assembly Cont d on page 33 TORQUE BOLTS TO 5 N m 44 n lb Copyright O 2011 ATSG 800 TORQUE CONVERTER HOUSING AXLE SEAL 801 TORQUE CONVERTER HOUSING ASSEMBLY Copyright O 2011 ATSG Figure 71 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information TRANSMISSION CASE ASSEMBLY AND ASSOCIATED PARTS 17 AUTOMATIC TRANSMISSION CASE ASSEMBLY 50 3RD GEAR BAND APPLY TUBE HOLD DOWN BRACKET RETAINING BOLT M6 x 1 0 x 14 2 Required 51 3RD GEAR BAND APPLY TUBE HOLD DOWN BRACKET 52 3RD GEAR BAND APPLY TUBE 53 3RD GEAR BAND APPLY TUBE O RING SEAL 2 Required 54 AUTOMATIC TRANSMISSION CASE PLUG M20 x 1 5 x 13 5 1 Required 55 AUTOMATIC TRANSMISSION CASE PLUG O RING SEAL 64 3RD GEAR BAND ANCHOR BOLT M20 x 1 5 x 21 1 Required 65 3RD GEAR BAND ANCHOR BOLT O RING SEAL 66 AUTOMATIC TRANSMISSION FLUID PRESSURE TEST PLUG UNF 5 16 24 2A 3 Required 67 AUTOMATIC TRANSMISSION FLUID PRESSURE TEST PLUG O RING SEAL 3 Required 68 TRANSMISSION CASE LOCATING DOWEL PIN 4 Required 70 TRANSMISSION LUBE FILL PLUG 80 AUTOMATIC TRANSMISSION AXLE SHAFT SEAL 83 TRANSMISSION LUBE FLUID TUBE HOLD DOWN BRACKET RETAINING BOLT M6 x 1 0 x 14 5 1
24. 1 25 x 15 5 mm control valve body downward as shown in Figure 254 cover attaching bolts into the case and torque the 109 Install the output sensor retaining bolt M6 x 1 0 x bolts to 13 N m 10 Ib ft as shown in Figure 253 16 mm and torque the bolt to 5 Nm 44 in Ib as shown in Figure 254 110 Install a new o ring seal onto the turbine sensor TORQUE ALL BOLTS IN THE and coat the o ring with a small amount of Trans SEQUENCE SHOWN TO Jel as shown in Figure 255 13 N m 10 Ib ft 111 Install the turbine sensor into the transmission case using a twisting motion while carefully pushing downward as shown in Figure 255 112 Install the turbine sensor retaining bolt M6 x 1 0 x 16 mm and torque the bolt to 5 Nm 44 in Ib as shown in Figure 255 Cont d on page 136 TORQUE THE OUTPUT SENSOR TORQUE THE TURBINE SENSOR RETAINING BOLT TO RETAINING BOLT TO 5 N m 44 in lb ve 5 N m 44 in b S Copyright 2011 ATSG Figure 254 OF mm 255 AUTOMATIC TRANSMISSION SERVICE GROUP 155 ATSG TRANSAXLE FINAL ASSEMBLY Cont d 113 Install the park neutral position switch onto the manual shift detent lever assembly as shown in Figure 256 114 Install the park neutral position switch flat washers and the stud and bolt and hand tighten enough so the switch will still rotate and allow adjustment by hand as shown in Figure 256 115 Install the park neutral position switch flat washer locking tab washer and nut as shown in Figur
25. 2 Reverse planetary carrier aside for cleaning and component rebuild 70 Remove the 1 2 Reverse internal gear front thrust bearing assembly as shown in Figure 49 71 Remove the 1 2 Reverse internal gear from the transmission as shown in Figure 49 72 Remove the 1 2 Reverse internal gear race and lower thrust bearing assembly from the lower side of the internal gear as shown in Figure 49 Copyright 2011 ATSG Figure 49 Technical Service Information 73 Using a pair of snap ring pliers remove the snap ring that retains the cover of the 3rd gear B4 band servo as shown in Figure 50 74 Remove the 3rd gear B4 band servo cover as shown in Figure 50 75 Remove and discard the o rings from the servo cover 76 Remove the 3rd gear B4 band servo and return spring as shown in Figure 50 77 Set the servo assembly aside for cleaning and component rebuild Remove the twelve transmission case rear cover attaching bolts from the transmission case as shown in Figure 51 Cont d on page 27 Copyright O 2011 ATSG Imm 51 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG TRANSAXLE DISASSEMBLY CONT D 78 Using a soft faced hammer or plastic mallet gently tap and loosen the transmission rear case cover as shown in Figure 52 79 Set the transmission rear case cover aside for cleaning and component rebuild 80 Remove and discard the five case fluid passage seals as shown in Figure 53 81 Remove the forward C1 and di
26. 2011 ATSG Figure 130 Automatic Transmission Rear Cover 1 2 Reverse Brake B5 Housing Assembly 1 Disassemble the Automatic Transmission Rear Cover 1 2 Reverse Brake B5 Housing Assembly using the diagram in Figure 127 as a guide 2 Clean all 1 2 Reverse Brake BS Housing Assembly parts with solvent 3 Blow dry all parts with compressed air 4 lnspect 1 2 Reverse Brake B5 Housing Assembly parts for wear or defect and replace as necessary 5 Inspect the Front Differential Transfer Drive Gear Assembly Rear Bearing Assembly and the Turbine Shaft Rear Support Bearing as shown in Figure 129 6 Install a new Front Differential Transfer Drive Gear Assembly Rear Lubrication Sealing Ring and coat the seal with a small amount of Trans Jel as shown in Figure 129 7 Install a new 1 2 Reverse Brake B5 Piston Inner and Outer O Ring Seal onto the Piston as shown in Figure 130 8 Coat the O Rings with a small amount of Trans Jel 9 Install the 1 2 Reverse Brake B5 Piston into the housing assembly by pushing down firmly and gently as shown in Figure 130 Cont d on page 66 600 1 2 REVERSE BRAKE B5 PISTON RETURN SPRING RETAINING SNAP RING 601 1 2 REVERSE BRAKE B5 PISTON RETURN SPRING 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY Copyright 2011 ATSG Figure 131 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Automatic Transmission Rear Cover 1 2 Reverse Brake b5 Housi
27. 43 57 Remove the parking pawl pin spring and the guide sleeve spacer as shown in Figure 43 58 Remove the parking pawl spring guide pin as shown in Figure 44 59 Remove the front differential transfer drive gear thrust bearing from the transfer drive gear assembly as shown in Figure 45 60 Remove the front differential transfer drive gear thrust bearing race from the transfer drive gear assembly as shown in Figure 45 61 Using Universal Clamp Press J 45053 or other adequate puller device attach the clamp and carefully remove the front differential transfer drive gear assembly from the transmission case as shown in Figure 45 62 Set the transfer drive gear assembly aside for cleaning and component rebuild Ne KJE Se an E 3 J Copyright 2011 ATSG igure 44 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 63 Remove the 4 5 clutch drum assembly as shown in Figure 46 64 Set the 4 5 clutch drum assembly aside for cleaning and component rebuild 65 Remove the third gear B4 band assembly from the case as shown in Figure 47 Cont d on page 26 Figure VJ ARTS TRANSAXLE DISASSEMBLY CONT D 66 Remove the upper 1 2 Reverse planet carrier thrust washer as shown on the previous page in Figure 47 67 Remove the 1 2 Reverse planet carrier assembly as shown in Figure 48 68 Remove the lower 1 2 Reverse planet carrier thrust washer as shown in Figure 48 69 Set the 1
28. 5 Install the two exhaust check valve springs and the check valves and the C1 accumulator ball 12 into the valve body as shown in Figure 173 OF ai Na AO M S 18 SOLENOID OIL FILTER S2 S3 S4 19 SOLENOID OIL FILTER S1 S5 20 ACCUMULATOR CHECK VALVE 104 CONTROL VALVE BODY BOLT M5 X 0 8 X 50 mm 2 Required 121 MIDDLE CONTROL VALVE BODY ASSEMBLY Copyright O 2011 ATSG Figure 172 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 52 Install the front control valve body spacer plate to front control valve body gasket the spacer plate and the front control valve body spacer plate to middle control valve body gasket as shown in Figure 173 53 Align the bolt holes in the gaskets and spacer plate with the bolt holes in the front control valve body Use a small amount of Trans Jel to hold gaskets in place if necessary Cont d on page 92 SOLENOID MODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRING FORWARD CLUTCH C1 ACCUMULATOR BALL 12 EXHAUST CHECK VALVE EXHAUST CHECK VALVE SPRING FRONT CONTROL VALVE BODY ASSEMBLY FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE FRONT CONTROL VALVE BODY SPACER PLATE TO MIDDLE CONTROL VALVE BODY GASKET Copyright O 2011 ATSG Figure 173 e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 54
29. 50mm 2 REQUIRED REVERSE SHIFT SOLENOID S5 CONNECTOR BROWN SHIFT SOLENOID VALVE O RING SEAL 5 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 REQUIRED 2 3 3 4 SHIFT SOLENOID S2 CONNECTOR BLACK REVERSE 1ST SHIFT SOLENOID S1 CONNECTOR BLACK CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 REQUIRED SOLENOID HOLD DOWN BRACKET SOLENOID SLS SLT CONTROL VALVE BODY BOLT M5 X 0 8 X 20 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 16 mm 2 REQUIRED FRONT CONTROL VALVE BODY ASSEMBLY LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR BLUE 116 A T INTERNAL WIRE HARNESS CLIP 117 118 119 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE Figure 195 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 FRONT CONTROL VALVE BODY SPACER PLATE MIDDLE CONTROL VALVE BODY GASKET MIDDLE CONTROL VALVE BODY ASSEMBLY MIDDLE CONTROL VALVE BODY ASSEMBLY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND BONDED GASKETS REAR CONTROL VALVE BODY ASSEMBLY REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY ASSEMBLY GASKET REAR CONTROL VALVE BODY SPACER PLATE REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKET NO 2 REAR CONTROL VALVE BODY A
30. Assembly 1 Disassemble the transmission case assembly using the diagram in Figure 72 and Figure 73 as a guide 2 Using SST J45201 or other adequate seal removing tool remove the two automatic transmission fluid cooler line seals as shown in Figure 74 3 Using a screwdriver carefully pry upward and remove the manual shift shaft seal as shown in Figure 75 4 Using SST J 45161 or other similar driver and a hammer drive the manual shift shaft bearing assembly through the case bore and remove the bearing assembly as shown in Figure 75 5 Using SST J 45000 or other adequate seal puller remove the automatic transmission axle seal as shown in Figure 76 87 AUTOMATIC TRANSMISSION FLUID COOLER LINE SEALS 2 Required Copyright O 2011 ATSG Figure 74 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 713 MANUAL SHIFT SHAFT SEAL 714 MANUAL SHIFT SHAFT BEARING ASSEMBLY Copyright O 2011 ATSG Figure 75 Figure 76 e ATSG Technical Service Information COMPONENT REBUILD CONT D Transmission Case Assembly 6 Clean all case assembly parts thoroughly with solvent and dry with compressed air 7 Inspect all transmission case assembly parts for wear and or damage and replace as necessary CAUTION It is vital to check the transmission case assembly for wear in the area where the drive transfer gear bearing support sleeve contacts the case as shown in Figure 77 If the case is worn in this area it wil
31. CHECK VALVE SPRING ID WHITE REVERSE INHIBIT CHECK BALL INNER BUSHING REVERSE INHIBIT CHECK BALL REVERSE INHIBIT CHECK BALL OUTER BUSHING LOCK UP CONTROL VALVE LOCK UP CONTROL VALVE PLUNGER LOCK UP CONTROL VALVE SPRING ID NONE LOCK UP CONTROL VALVE SLEEVE BORE PLUG RETAINER 1 3 2 X 5 X 21 2 mm Copyright 2011 ATSG 121 PAATSG PRESSURE RELIEF VALVE SPRING 4 WIRE DIAMETER 050 OUTSIDE DIAMETER 370 OVERALL LENGTH 1 128 COILS 5 COLOR ID NONE SOLENOID RELAY VALVE SPRING 25 WIRE DIAMETER 019 OUTSIDE DIAMETER 235 OVERALL LENGTH 800 COILS 9 COLOR ID RED U1 SHIFT VALVE SPRING 40 WIRE DIAMETER 032 OUTSIDE DIAMETER 397 OVERALL LENGTH 1 020 COILS 7 COLOR ID LT GREEN LOCK UP RELAY VALVE SPRING 51 WIRE DIAMETER 022 OUTSIDE DIAMETER 231 OVERALL LENGTH 0 940 COILS 12 COLOR ID RED SHIFT PRESSURE CONTROL VALVE SPRING 63 WIRE DIAMETER 025 OUTSIDE DIAMETER 229 OVERALL LENGTH 0 620 COILS 12 COLOR ID WHITE B2 CONTROL VALVE SPRING 79 WIRE DIAMETER 032 OUTSIDE DIAMETER 382 OVERALL LENGTH 1 356 COILS 9 COLOR ID NONE Technical Service Information CONTROL VALVE BODY ASSEMBLY SPRING SPECIFICATIONS LATE VALVE BODY ID STAMP C SOLENOID MODULATOR VALVE SPRING 10 WIRE DIAMETER 043 OUTSIDE DIAMETER 315 OVERALL LENGTH 1 113 COILS 12 COLOR ID YELLOW PRESSURE REGULATOR VALVE SPRING 30 WIRE DIAMETER 047 OUTSIDE DIA
32. CLUTCH B5 CONTROL VALVE COVER PLATE ATTACHING BOLT 2 Required REAR CONTROL VALVE BODY COVER PLATE REAR CONTROL VALVE BODY COVER PLATE GASKET SECONDARY REGULATOR VALVE SECONDARY REGULATOR VALVE SPRING SOLENOID SLT ACCUMULATOR PISTON SLT ACCUMULATOR OUTER SPRING SLT ACCUMULATOR INNER SPRING 62 63 64 65 66 67 68 69 70 71 72 73 74 75 Figure 165 AUTOMATIC TRANSMISSION SERVICE GROUP SHIFT PRESSURE CONTROL VALVE SLEEVE SHIFT PRESSURE CONTROL VALVE SPRING SHIFT PRESSURE CONTROL VALVE SHIFT PRESSURE CONTROL VALVE PLUNGER SHIFT PRESSURE CONTROL VALVE PLUNGER SLEEVE M2 SHIFT VALVE M2 SHIFT VALVE SPRING SHIFT PRESSURE RELAY VALVE SHIFT PRESSURE RELAY VALVE SPRING B4 BAND CONTROL VALVE SPRING B4 BAND CONTROL VALVE REAR CONTROL VALVE BODY COVER PLATE GASKET REAR CONTROL VALVE BODY COVER PLATE COVER PLATE ATTACHING BOLT 7 Required Copyright 2011 ATSG e ATSG Technical Service Information MIDDLE CONTROL VALVE BODY EXPLODED VIEW SCH f AUNE IJ HA WO IO id o o h 17 MIDDLE CONTROL VALVE BODY 31 PRESSURE REGULATOR VALVE PLUNGER 18 SOLENOID OIL FILTER S2 S3 S4 32 PRESSURE REGULATOR VALVE SLEEVE 19 SOLENOID OIL FILTER S1 S5 33 U2 SHIFT VALVE 20 ACCUMULATOR CHECK VALVE 34 U2 SHIFT VALVE SPRING 21 BORE PLUG RETAINER 7 3 2 X 5 X 12 5 mm 35 BORE PLUG 3 22 SOLENOID RELAY VALVE SLEEVE 36 M1 SHIFT VALVE 23 SOLENOID RELAY VALVE PLUNGER 37 M1 S
33. GASKET 125 REAR CONTROL VALVE BODY SPACER PLATE 126 REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKET 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY Copyright 2011 ATSG Figure 163 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG COMPONENT REBUILD Control Valve Body Assembly Cont d 22 Disassemble the No 2 rear control valve body using the diagram in Figure 164 as a guide Place all valves and springs into an appropriate tray exactly as they were removed 23 Clean all No 2 rear control valve body parts with solvent and dry with compressed air 24 Assemble the No 2 rear control valve body using the diagram in Figure 164 as a guide Lubricate all valves with a small amount of ATF during installation Note the 2nd clutch B2 control valve plug is stepped and adjustable and should be marked before removal to ensure the retainer is relocated in the factory specified setting 25 Remove the rear control valve body cover plate attaching bolts using an 8 mm socket then disassemble the rear control valve body using the diagram in Figure 165 as a guide Technical Service Information 26 Place all valves and springs into an appropriate tray exactly as they were removed 27 Clean all rear control valve body parts with solvent and dry with compressed air 28 Assemble the rear control valve body using the diagram in Figure 165 as a guide Lubricate all valves with a small amount of ATF during installatio
34. M5 X 0 8 X 76 mm 1 REQUIRED 129 CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 mm 4 REQUIRED 130 CONTROL VALVE BODY BOLT M5 X 0 8 X 40 mm 1 REQUIRED 131 CONTROL VALVE BODY ASSEMBLY PRESSURE TEST PORT BOLT M6 X 1 0 X 12 mm 1 REQUIRED 132 CONTROL VALVE BODY BOLT M5 X 0 8 X 35 mm 2 REQUIRED 133 MANUAL VALVE LINK 134 MANUAL VALVE 135 MANUAL VALVE LINK RETAINING CLIP 136 TCC PRESSURE CONTROL SOLENOID SLU CONNECTOR BLACK 137 SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR GREEN Copyright 2011 ATSG Figure 202 117 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT CONTROL VALVE BODY ga 33333333 93535353 23333533 33333353 23353533 RSS 23333333 53505359 ROY 253535 RS AN INY WC h AS U p VA V S DW US N NS N IG SN Y Bo Da SQ 4 RD i N gt 16 S g De 9 Copyright 2011 ATSG Figure 203 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information ATSG MIDDLE CONTROL VALVE BODY Copyright O 2011 ATSG Figure 204 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information REAR CONTROL VALVE BODY NO 2 REAR CONTROL VALVE BODY 55 Copyright 2011 ATSG Figure 205 120 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND FRONT CONTROL VALVE BODY SOLENOID M
35. PURPLE PRESSURE REGULATOR VALVE PLUNGER PRESSURE REGULATOR VALVE SLEEVE U2 SHIFT VALVE U2 SHIFT VALVE SPRING ID LT GREEN BORE PLUG 3 M1 SHIFT VALVE M1 SHIFT VALVE SPRING ID LT GREEN M1 SHIFT VALVE BORE PLUG 1 U1 SHIFT VALVE U1 SHIFT VALVE SPRING ID LT GREEN BA RELEASE VALVE SPRING ID BLUE BA RELEASE VALVE MANUAL VALVE COOLER BYPASS VALVE COOLER BYPASS VALVE SPRING ID NONE Figure 185 AUTOMATIC TRANSMISSION SERVICE GROUP TCC CHECK VALVE CHECK VALVE SPRING ID YELLOW REAR CONTROL VALVE BODY LOCK UP RELAY CONTROL VALVE SLEEVE LOCK UP RELAY CONTROL VALVE PLUNGER LOCK UP RELAY CONTROL VALVE SPRING ID RED LOCK UP RELAY CONTROL VALVE 1 2 REVERSE CLUTCH B5 CONTROL VALVE COVER PLATE ATTACHING BOLT 2 REQUIRED REAR CONTROL VALVE BODY COVER PLATE REAR CONTROL VALVE BODY COVER PLATE GASKET SECONDARY REGULATOR VALVE SECONDARY REGULATOR VALVE SPRING ID NONE SOLENOID SLT ACCUMULATOR PISTON SLT ACCUMULATOR OUTER SPRING ID PINK SLT ACCUMULATOR INNER SPRING ID PINK SHIFT PRESSURE CONTROL VALVE SLEEVE SHIFT PRESSURE CONTROL VALVE SPRING ID WHITE SHIFT PRESSURE CONTROL VALVE SHIFT PRESSURE CONTROL VALVE PLUNGER SHIFT PRESSURE CONTROL VALVE PLUNGER SLEEVE M2 SHIFT VALVE M2 SHIFT VALVE SPRING ID LT BLUE SHIFT PRESSURE RELAY VALVE SHIFT PRESSURE RELAY VALVE SPRING ID LT GREEN BA B
36. Piston Seal with a small amount of Trans Jel then install the accumulator piston with a twisting motion into the 1 2 Reverse Brake B5 housing as shown in Figure 134 26 Install the Accumulator Cushion Spring as shown in Figure 134 27 Coat the Accumulator Housing O ring seal with a small amount of Trans Jel and install the accumulator housing by pushing downward with a slight twisting motion so it compresses the spring then install one of the two attaching bolts and hand tighten the bolt as shown in Figure 134 Cont d on page 68 Technical Service Information Do Not Install This Bolt Now 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY 607 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING FLUID SEALING RINGS 3 REQUIRED 608 4 5 CLUTCH C3 APPLY TUBE O RING SEALS 2 REQUIRED 609 4 5 CLUTCH C3 APPLY TUBE 610 4 5 CLUTCH C3 APPLY TUBE RETAINING BRACKETS 2 REQUIRED 611 4 5 CLUTCH C3 APPLY TUBE RETAINING BRACKET ATTACHING BOLTS M5 x 0 8 X 12 MM 4 REQUIRED 612 FORWARD CLUTCH C1 ACCUMULATOR PISTON 613 FORWARD CLUTCH C1 ACCUMULATOR PISTON FLUID SEALING RING 614 FORWARD CLUTCH C1 ACCUMULATOR PISTON CUSHION SPRING ID COLOR NATURAL 615 FORWARD CLUTCH C1 ACCUMULATOR COVER O RING SEAL 616 FORWARD CLUTCH C1 ACCUMULATOR HOUSING 617 FORWARD CLUTCH C1 ACCUMULATOR HOUSING ATTACHING BOLT M5 x 0 8 X 12 MM 2 REQUIRED 628 FORWARD C1 AND DIRECT C2 CLUTCH D
37. Required 84 TRANSMISSION LUBE FLUID TUBE HOLD DOWN BRACKET 85 TRANSMISSION LUBE FLUID TUBE 86 AUTOMATIC TRANSMISSION CASE FLUID PASSAGE SEAL 7 Required 87 AUTOMATIC TRANSMISSION FLUID COOLER LINE SEAL 2 Required 88 FRONT DIFFERENTIAL ASSEMBLY BEARING RACE SELECTIVE SHIM 1 Required 89 AUTOMATIC TRANSMISSION CASE FLUID PASSAGE SEAL 1 Required 90 FRONT DIFFERENTIAL ASSEMBLY BEARING RACE Copyright 2011 ATSG Figure 72 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TRANSMISSION CASE ASSEMBLY PARK PAWL AND SHIFT LINKAGE ASSEMBLY S el D 2 NN S 705 TF 700 PARK PAWL SHAFT 701 PARK PAWL RETURN SPRING 702 PARK PAWL 703 PARK PAWL SPRING PIN 704 PARK PAWL PIN SPRING 705 PARK PAWL PIN SPRING GUIDE SLEEVE 706 PARK PAWL PIN SPRING RETAINING BOLT M6 x 1 0 x 25 1 Required 707 AUTOMATIC TRANSMISSION CASE ASSEMBLY 708 PARK PAWL ACTUATOR BRACKET 712 MANUAL SHAFT DETENT LEVER SPRING HOLD DOWN BRACKET RETAINING BOLT M6 x 1 0 x 14 1 Required 709 PARK PAWL ACTUATOR ROD 713 MANUAL SHIFT SHAFT SEAL 710 MANUAL SHAFT DETENT LEVER 714 MANUAL SHIFT SHAFT BEARING ASSEMBLY 711 MANUAL SHAFT DETENT LEVER SPRING 715 PARK PAWL ACTUATOR BRACKET HOLD DOWN BRACKET RETAINING BOLT M6 x 1 0 x 16 7 1 Required Copyright 2011 ATSG Figure 73 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS COMPONENT REBUILD CONT D Transmission Case
38. Required Apply Threadlocker GM P N 12345382 or Equivalent to each bolt 20 Copyright 2011 ATSG before installing Figure 222 i e Vi AE Copyright O 2011 ATSG Xm Copyright 2011 ATSG Figure 220 Figure 223 126 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 37 Install a new third gear B4 band into the transmission as shown in Figure 224 38 Make sure the 1 2 Reverse carrier thrust washer does not become dislodged from the carrier as shown in Figure 224 39 Install the 4 5 C3 clutch drum assembly with a twisting motion as shown in Figure 225 40 Install the servo assembly into the case then install and tap the cover into the case using a soft faced mallet and install the retaining snap ring as shown in Figure 226 Caution Wear Safety glasses when using compressed air to prevent eye injury 41 Measure the servo travel using the diagram and instructions in Figure 227 42 If servo travel is not within specification select a different length servo pin to obtain specified servo travel 43 See Page 75 Figure 148 for servo travel specifications Cont d on page 128 MEE re co AER Make a mark on the servo piston pin with the servo in its released position This is Mark 1 2 Apply compressed air to the servo apply port indicated by the number 3 3 With the servo pis
39. SNAP RING 604 1 2 REVERSE BRAKE B5 PISTON OUTER O RING SEAL 623 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEMBLY REAR BEARING ASSEMBLY 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY 624 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEMBLY REAR LUBRICATION SEALING RING 607 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING FLUID SEALING RINGS 3 REQUIRED 625 TURBINE SHAFT REAR SUPPORT BEARING 608 4 5 CLUTCH C3 APPLY TUBE O RING SEALS 628 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING 2 REQUIRED THRUST BEARING RACE 609 4 5 CLUTCH C3 APPLY TUBE 610 4 5 CLUTCH C3 APPLY TUBE RETAINING BRACKETS 2 REQUIRED 611 4 5 CLUTCH C3 APPLY TUBE RETAINING BRACKET ATTACHING BOLTS M5 x 0 8 x 12 MM 4 REQUIRED Copyright O 2011 ATSG Figure 128 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY 623 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEMBLY REAR BEARING ASSEMBLY 624 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEMBLY REAR LUBRICATION SEALING RING 625 TURBINE SHAFT REAR SUPPORT BEARING Copyright 2011 ATSG Figure 129 602 1 2 REVERSE BRAKE B5 PISTON INNER O RING SEAL 603 1 2 REVERSE BRAKE B5 PISTON ASSEMBLY 604 1 2 REVERSE BRAKE B5 PISTON OUTER O RING SEAL 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY Copyright
40. TO NO 2 REAR CONTROL VALVE BODY GASKET 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY 128 CONTROL VALVE BODY BOLT M5 X 0 8 X 76 mm 1 REQUIRED 129 CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 mm 4 REQUIRED 130 CONTROL VALVE BODY BOLT M5 X 0 8 X 40 mm 1 REQUIRED 131 CONTROL VALVE BODY ASSEMBLY PRESSURE TEST PORT BOLT M6 X 1 0 X 12 mm 1 REQUIRED 132 CONTROL VALVE BODY BOLT M5 X 0 8 X 35 mm 2 REQUIRED 133 MANUAL VALVE LINK 134 MANUAL VALVE 135 MANUAL VALVE LINK RETAINING CLIP 136 TCC PRESSURE CONTROL SOLENOID SLU CONNECTOR BLACK 137 SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR GREEN Copyright 2011 ATSG Figure 188 103 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT CONTROL VALVE BODY D 10 amp 3 Y mm IL DU S p S 2 12 lt Q S 16 gt Set N 9 Copyright O 2011 ATSG Figure 189 104 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PAATSG MIDDLE CONTROL VALVE BODY NL Ir mm GN MAW VA 2 Th Tarte ENT N VANNU ae 0 ONY Vi Copyright 2011 ATSG Figure 190 AUTOMATIC TRANSMISSION SERVICE GROUP 105 e ATSG Technical Service Information REAR CONTROL VALVE BODY NO 2 REAR CONTROL VALVE BODY 55 Copyright 2011 ATSG Figure 191 106 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG 0 00 N Technical Service Information CON
41. all 4 5 Clutch C3 Assembly parts thoroughly and dry with compressed air 3 Inspect all 4 5 Clutch C3 Assembly parts for wear and or damage replace as necessary 4 Install a new Inner O ring Seal and a new Outer O ring Seal on the 4 5 Clutch C3 Piston as shown 1n Figure 138 5 Coat both O ring seals with a small amount of Trans Jel 581 4 5 CLUTCH C3 PISTON INNER O RING SEAL 582 4 5 CLUTCH C3 PISTON ASSEMBLY 583 4 5 CLUTCH C3 PISTON OUTER O RING SEAL 584 4 5 CLUTCH C3 DRUM ASSEMBLY Copyright 2011 ATSG Figure 138 Technical Service Information 6 Install the 4 5 Clutch C3 Piston Assembly into the drum by carefully pushing downward with your hand as shown in Figure 138 7 Install the 4 5 Clutch C3 Piston Return Spring Assembly into the clutch piston as shown in Figure 139 8 Using SST J 23327 J 25024 A and J 45186 or similar spring compression tools carefully compress the 4 5 Clutch C3 Piston Return Spring and install the 4 5 Clutch C3 Piston Return Spring Retaining Snap Ring as shown in Figure 139 Be careful not to bend the return spring assembly 9 Make sure the retaining snap ring 1s fully seated in the snap ring groove Cont d on page 71 579 4 5 CLUTCH C3 PISTON RETURN SPRING ASSEMBLY RETAINING SNAP RING 580 4 5 CLUTCH C3 PISTON RETURN SPRING ASSEMBLY 584 4 5 CLUTCH C3 DRUM ASSEMBLY Copyright 2011 ATSG Figure 139 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS
42. appropriate torque wrench torque the twelve converter housing attaching bolts to 29 Nm 21 ft Ib in a cross wise fashion using the pattern shown in Figure 82 3 TORQUE CONVERTER HOUSING STUD M8 x 1 25 x 30 2 Required 4 TORQUE CONVERTER HOUSING BOLT M8 x 1 25 x 30 9 Required 8 TORQUE CONVERTER HOUSING BOLT TORX M8 x 1 25 x 30 1 Required Cont d on page 38 Copyright 2011 ATSG Figure 81 Torque The Converter Housing Bolts To 29 N m 27 ft lb 13 FRONT DIFFERENTIAL ASSEMBLY 17 AUTOMATIC TRANSMISSION CASE ASSEMBLY Copyright 2011 ATSG Figure 80 Figure 82 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD CONT D Choosing Front Differential Bearing Race Rotational Torque Measurement Selective Shim 4 Using SST DT 47687 or other similar rotational 9 Remove the rotational torque adapter tool from torque adapter tool insert the tool into the axle the front differential and remove the torque shaft opening in the converter housing and turn converter housing and differential assembly from the adapter so it engages the differential pinion the transmission case assembly cross shaft as shown in Figure 83 10 Using SST J 45160 differential bearing race 5 Using an appropriate torque wrench measure the remover and J 45124 removal bridge or other rotational torque required to slowly rotate the adequate bearing race removal tool remove the front differential asse
43. assembly with solvent and dry with compressed air 2 Inspect the differential assembly for wear or damage using the diagram in Figure 88 as a reference If any wear or damage is observed replace the differential assembly Note It is not recommended to disassemble the Front Differential Transfer Drive Gear Assembly The exploded view diagram shown in Figure 89 is provided for illustration purposes only 1 Clean the Front Differential Transfer Drive Gear Assembly with solvent and dry with compressed air 2 Inspect the Front Differential Transfer Drive Gear Assembly for wear or damage using the diagram in Figure 89 asa reference If any wear or damage is observed replace the assembly Oil Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly 1 Disassemble the Oil Pump Assembly Second Coast Brake Bl and Second Brake B2 Assembly using the diagram in Figure 90 and the legend in Figure 91 as a guide 2 Using SST J 23327 Spring Compressor or other similar tool compress the Second Brake B2 spring then using SST J28585 or a small screw driver remove the Second Coast Brake Bl Backing Plate Retaining Snap Ring the Second Coast Brake B1 Backing Plate the Second Coast Brake B1 Lined Plates discard the lined plates and the Second Coast Brake B1 Steel plates as shown in Figure 92 3 Using SST J 23327 and J 41236 or other similar spring compressor tool compress the Second Coast Brake B1 Piston Return Sprin
44. below 68 degrees F Driving When ascending a grade or driving uphill the control module will alter the shift pattern Uphill to reduce busy shifting Towing or driving with a heavy load can have the same result This function 1s not available on all models The control module will release the forward clutch C1 at a stop with the brake applied to reduce engine load vibration and improve fuel economy When the brake is released the forward clutch engages This operating strategy will make a 2 footed driver crazy The following conditions must be Neutral met to allow Neutral Control function Manual shifter must be in D 4 or 3 Neutral Control Control will not work 1f Winter Mode or Geartronic operation 1s selected Trans oil temp must be over 50 degrees F Throttle position must be less than 3 Brake pedal must be depressed Vehicle speed must be 0 MPH Engine RPM less than 1500 There is a 2 second delay to neutral when the vehicle is stopped in the D position and a 5 second delay to neutral when shifted from N to D range AUTOMATIC TRANSMISSION SERVICE GROUP 153 PGATSG Technical Service Information AW55 50 SN SERIES OPERATING MODES VOLVO SHIFTING USING GEARTRONIC When the shifter is placed into the Geartronic position the transmission remains in the hydraulic D range When the shifter 1s moved to the or positions the gear selector module sends a signal to the TCM to shift the transmission up or down The driver infor
45. control valve body bolt 107 using a torque 62 wrench and an 8 mm socket and torque to 7 Nm 62 in Ib as shown in Figure 178 Install the manual valve into the valve body as 63 shown in Figure 179 Set control valve body assembly aside for final 64 assembly The following valve body diagrams in Figures 180 65 thru 207 on pages 95 thru 122 detail the differences in the four valve body types They are classified TORQUE CONTROL VALVE BODY early to late by their respective ID stamps located ATTACHING iat 70 on top of the Front Control Valve Body Assembly as shown in Figure 179 and can be identified by No ID Stamp ID Stamp A ID Stamp and ID Stamp ID Stamp Location Example D Stamp 107 CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 Required 110 CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 Required 111 SOLENOID HOLD DOWN BRACKET Solenoid SLS SLT 115 LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR Blue 116 A T INTERNAL WIRE HARNESS CLIP 117 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET 136 TCC PRESSURE CONTROL SOLENOID SLU CONNECTOR Black 137 SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR Green 133 MANUAL VALVE LINK 134 MANUAL VALVE 135 MANUAL VALVE LINK RETAINING CLIP Copyright 2011 ATSG Figure 178 Figure 179 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright 2011 ATSG ARTS Technical Service Information CONTROL VALVE BODY ASSEM
46. g R 9 Copyright O 2009 ATSG Figure 182 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information ATSG MIDDLE CONTROL VALVE BODY Copyright O 2009 ATSG Figure 183 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information REAR CONTROL VALVE BODY NO 2 REAR CONTROL VALVE BODY 55 Copyright 2009 ATSG Figure 184 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND FRONT CONTROL VALVE BODY SOLENOID MODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRING ID NONE FORWARD CLUTCH C1 ACCUMULATOR BALL 12 BORE PLUG RETAINER 4 3 2 X 5 X 10 mm BORE PLUG 4 SOLENOID MODULATOR VALVE SPRING ID YELLOW SOLENOID MODULATOR VALVE FORWARD CLUTCH C1 CONTROL VALVE NEUTRAL RELAY VALVE NEUTRAL RELAY VALVE SPRING ID LT GREEN 2ND COAST B1 CONTROL VALVE SPRING ID BLUE 2ND COAST B1 CONTROL VALVE MIDDLE CONTROL VALVE BODY SOLENOID OIL FILTER S2 S3 S4 SOLENOID OIL FILTER S1 S5 ACCUMULATOR CHECK VALVE BORE PLUG RETAINER 7 3 2 X 5 X 12 5 mm SOLENOID RELAY VALVE SLEEVE SOLENOID RELAY VALVE PLUNGER SOLENOID RELAY VALVE SOLENOID RELAY VALVE SPRING ID RED REVERSE SHIFT CHECK BALL OUTER BUSHING REVERSE SHIFT CHECK BALL REVERSE SHIFT CHECK BALL INNER BUSHING PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE SPRING ID
47. required 15 Once proper shim has been selected and rotational torque measurement is within specification install the appropriate shim into the transmission case assembly as shown in Figure 86 16 Using SST J 8092 and J 45184 or other adequate driver and handle install a new front differential bearing race into the case as shown in Figure 87 17 Set the transmission case assembly aside for final assembly Cont d on page 40 Front Differential Bearing Race Selective Shims IDENTIFICATION Available Shims Figure 85 Copyright O 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 17 TRANSMISSION CASE ASSEMBLY 90 FRONT DIFFERENTIAL BEARING RACE Copyright O 2011 ATSG Figure 87 ATSG Technical Service Information FRONT DIFFERENTIAL ASSEMBLY EXPLODED VIEW df 630 FRONT DIFFERENTIAL SIDE GEAR THRUST WASHER SELECTIVE 2 REQUIRED 631 FRONT DIFFERENTIAL SIDE GEAR 2 REQUIRED 632 FRONT DIFFERENTIAL PINION SHAFT THRUST WASHER 4 REQUIRED 633 FRONT DIFFERENTIAL PINION GEAR 4 REQUIRED 635 FRONT DIFFERENTIAL RING GEAR 636 FRONT DIFFERENTIAL RING GEAR ATTACHING BOLT M11 X 1 0 X 34 12 REQUIRED 637 FRONT DIFFERENTIAL TAPERED ROLLER BEARING 86MM ID 637 639 639 FRONT DIFFERENTIAL PINION SHAFT RETAINING PIN 6MM x 38MM 3 REQUIRED 640 FRONT DIFFERENTIAL CARRIER ASSEMBLY 641 FRONT DIFFERENTIAL TAPERED ROLLER BEARING 90MM ID 642 FRONT DIFFERENTIAL P
48. solenoid passages will not be aligned with the valve body casting Figure 267 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AWSS 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE SOLENOID WIRE COLOR CHART SOLENOID LD SOLENOID CONNECTOR COLOR WIRE COLOR 1 GREEN SLU BLACK E 1 GREEN SOLENOID LOCATION For Nissan Units PCA SLT PCB SLS PCC SLU A SI 52 S3 D 54 E S5 Figure 268 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT CONTROL VALVE BODY CASTING DIFFERENCES NO ID STAMP ID STAMP C ID STAMP A ID STAMP B CASTING CASTING MIDDLE CONTROL VALVE BODY CASTING DIFFERENCES NO ID STAMP ID STAMP C ID STAMP STAMP B CASTING Figure 270 AUTOMATIC TRANSMISSION SERVICE GROUP 149 e ATSG Technical Service Information SPACER PLATE DIFFERENCES NO ID STAMP ID STAMP C ID STAMP A ID STAMP B SPACER PLATE SPACER PLATE Figure 271 NO ID STAMP ID STAMP C ID STAMP A ID STAMP B GASKETS DIFFERENCES GASKETS Figure 272 150 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG COMPLAINT CAUSE CORRECTION Technical Service Information AWSS 50 SN SERIES OPERATING MODES Vehicles equipped with the AW55 50SN series transaxles may exhibit what is perceived to be erratic shift operation such as delayed shifts sudden downshifts wrong gear starts or high gear sta
49. to Voltage P0768 TCM 0108 Shift Solenoid S4 Signal Missing Resistance Too High or Open Circuit A TCM 0109 Shift Solenoid S4 Signal Too Low Short to Ground POTIS TCM 010B Shift Solenoid S5 signal Too High Short to Voltage Signal Missing Resistance Too High or Open Circuit UM TCM 010A Shift Solenoid S5 A TCM 010C Shift Solenoid S5 Signal Too Low Short to Ground Se TCM 010D Lock Up Solenoid SLU TCM 010F Lock Up Solenoid SLU ae TCM 0110 Lock Up Solenoid SLU e TCM 0100 Poor Gear Shifting Quality P0798 P0799 TCM 0112 System Pressure Solenoid SLS P0971 P0800 P0801 TCM 0113 System Pressure Solenoid SLS P0968 Signal Too High Short to Voltage Intermittent or Permanent Error Signal Missing Resistance Too High or Open Circuit Intermittent or Permanent Error Signal Too Low Short to Ground Intermittent or Permanent Error Slipping or Missed Shifts Signal Too High Short to Voltage PO798 Intermittent Error PO799 Permanent Error Signal Missing Resistance Too High or Open Circuit P0800 Intermittent Error PO801 Permanent Error ne TCM 0114 System Pressure Solenoid SLS Signal Too Low Short to Ground P0802 Intermittent P0970 Error P0803 Permanent Error P0810 P1700 TCM 012A Neuial Check P1700 TCM 012A Incorrect Connection P1516 TCM 012B P1516 TCM 012B No Neutral Check de TCM 012C Neutral Check P0928 Solenoid P Position Shift Lock Signal Missing P0930 Solenoid P Positi
50. with a small amount of ATF or Trans Jel and install the sprag into the Second Brake B2 Outer Race as shown in Figure 116 5 Install the Second Brake Sprag F1 End Bearings as shown in Figure 116 6 Coat the Second Coast Brake B1 Thrust Washer with a small amount of Trans Jel and attach to the Second Coast Brake B1 Inner Race as shown in Figure 117 Cont d on page 58 500 SECOND COAST BRAKE B1 HUB SPRAG INNER RACE ASSEMBLY 501 SECOND COAST BRAKE B1 THRUST WASHER 505 SECOND BRAKE SPRAG F1 OUTER RACE AND B2 CLUTCH HUB ASSEMBLY Copyright 2011 ATSG Figure 117 The Second Coast Brake B1 Hub Sprag Inner Race must Freewheel Clockwise and Lock Counter Clockwise 502 SECOND BRAKE SPRAG F1 END BEARING 2 REQUIRED 503 SECOND BRAKE SPRAG F1 ASSEMBLY 505 SECOND BRAKE SPRAG F1 OUTER RACE AND B2 CLUTCH HUB ASSEMBLY Copyright 2011 ATSG Figure 116 Figure 118 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Second Coast Brake B1 Second Brake B2 Hub and Second Brake Sprag FI Assembly 9 Coat the Second Coast Brake B1 Clutch Hub Thrust Washer with a small amount of Trans Jel and install the washer on the Pump Assembly as shown in Figure 119 10 Install the Second Brake B2 Second Coast Brake B1 Hub and Sprag Assembly into the Pump Assembly using a twisting motion until it is indexed into all clutch plates and 1s seated against the washer as shown in Figure 119 1
51. with the AW55 50SN series transaxles may exhibit various erratic shifting problems bind up conditions and or complete transmission failure on initial road test after a valve body or solenoid repair or replacement The cause of any one or combination of the above complaints may be due to mis matching the valve body using an incorrect solenoid cross connecting internal harness connectors to the wrong solenoid or mis positioning the SLS SLT solenoid retaining bracket To properly identify your valve body assembly you must first check the casting next to the S4 solenoid for the presence of a capital letter 4 B or C Valve bodies that have no letter or show the letter A are early design assemblies first and second generation These valve bodies will also have the SLT and SLS solenoid connectors facing up as shown in Figure 259 Valve bodies with either letter B or C are late design assemblies third and fourth generation and will have the redesigned 3rd version SLT and SLS solenoids with the connectors facing down The S1 solenoid was also changed at this time with the connector relocated to the left and the mounting bracket to the right to allow clearance for the SLS solenoid connector now facing downward These changes also made a new internal harness necessary so that the wires will reach the relocated solenoid connectors as shown in Figure 260 The S1 through S5 solenoids are all ON OFF type solenoids that typically measure 11 16 ohms resistance
52. 0600 TCM E000 Control Module Communication P0602 TCM 0048 Control Module Defective Software P0614 P0605 Internal Error Intermittent Error P0601 TEM Kone Moen Internal Error Permanent Error P0605 P CODES FAULT DESCRIPTION P0712 TCM 0043 Oil Temperature Sensor Signal Too Low Temperature Too High P0713 TCM 0044 Oil Temperature Sensor Signal Too High Temperature Too Low P0715 TCM 0087 Transmission Input Speed Sensor Signal Too High or Short to Power ase TCM 0089 Transmission Input Speed Sensor Signal Too High or Short to Ground P0716 TCM 0024 Transmission Input Speed Sensor Incorrect Signal Intermittent or Permanent Error P0717 TCM 0023 Transmission Input Speed Sensor Signal Missing Intermittent or Permanent Error E P0731 TCM 0028 Incorrect Gear Ratio First Gear P0732 TCM 0029 Incorrect Gear Ratio Second Gear NOTE CODES IN BOLD TYPE ARE FOR 2002 LATER MODELS Copyright O 2011 ATSG Figure 279 164 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information DIAGNOSTIC TROUBLE CODES DTC S VOLVO P CODES VOLVO PG NN FAULT DESCRIPTION OEM CODES CODE DTC DESCRIPTION d TCM 002F Lock Up Function Torque Converter Clutch Slipping or Stuck Off P0744 TCM 002E Lock Up Function Torque Converter Clutch Registers Repeated Vibration d signal Too High Permanent Error pr Signal Too High Intermittent Error om Signal Missing Permanent Error Ai Signal Missing Intermittent Er
53. 1 Coat the Second Brake Sprag F1 Outer Race and Clutch Hub Thrust Washer with a small amount of Trans Jel and install onto the sprag assembly as shown in Figure 119 2 OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND SECOND BRAKE B2 ASSEMBLY 5 SECOND BRAKE B2 SECOND COAST BRAKE B1 HUB AND SPRAG ASSEMBLY 226 SECOND COAST BRAKE B1 CLUTCH HUB THRUST WASHER 506 SECOND BRAKE B2 SPRAG OUTER RACE AND CLUTCH HUB ASSEMBLY THRUST WASHER Copyright 2011 ATSG Figure 119 Technical Service Information 12 Use a straight edge to measure the installed height of the Second Brake B2 Second Coast Brake B1 Hub and Sprag Assembly by placing the straight edge on top of the thrust washer and making a measurement between the bottom of the straight edge and the face of the pump body as shown in Figure 120 13 1 the installed height is greater than the specification shown in Figure 120 the hub and sprag assembly is not indexed correctly Remove and reinstall until the installed height is within the specifications 14 Set the completed pump assembly aside for final assembly Checking Installed Height Clearance Measure distance between the arrows Height Specification Installed Height 51 09 51 71 mm 2 011 2 036 in Copyright 2011 ATSG Figure 120 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FORWARD C7 AND DIRECT C2 CLUTCH ASSEMBLY EXPLODED VIEW 559 DIRE
54. 3 Universal Clamp Press J 45124 Removal Bridge J 45159 Holding Fixture J 45160 Differential Bearing Race Remover Figure 284 AUTOMATIC TRANSMISSION SERVICE GROUP J 35582 Oil Pump Seal Installer J 36850 Trans jel Lubricant J 41236 Coast Clutch Spring Compressor J 41239 1A Cooler Line Seal Installer J 44809 Output Shaft Seal Installer Copyright 2011 ATSG ATSG Technical Service Information SPECIAL SERVICE TOOLS SST SECTION J 23327 Clutch Spring Compressor J 23456 Booster and Clutch Pack Compressor J 25024 A Servo Piston Clutch Spring Compressor J 28585 Snap Ring Remover Figure 285 AUTOMATIC TRANSMISSION SERVICE GROUP DT 47599 Anchor Bolt Socket DT 47687 Rotational Torque Adapter J 3289 20 Holding Fixture J 8092 Driver Handle Copyright 2011 ATSG
55. 4 4 Remove three transmission fluid baffle retaining bolts and the baffle as shown in Figure 64 5 Carefully remove the transmission fluid lube tube as shown in Figure 65 800 TORQUE CONVERTER HOUSING AXLE SEAL 801 TORQUE CONVERTER HOUSING ASSEMBLY Cont d on page 31 Copyright 2011 ATSG 803 AUTOMATIC TRANSMISSION FLUID BAFFLE 805 LUBE FLUID TUBE HOLD DOWN BRACKET 806 LUBE FLUID TUBE BRACKET RETAINING BOLT 801 TORQUE CONVERTER HOUSING ASSEMBLY M6 X 1 0 X 14 1 REQUIRED 804 TRANSMISSION LUBE FLUID TUBE 807 TRANSMISSION FLUID BAFFLE RETAINING BOLT M6 X 1 0 X 14 3 REQUIRED Copyright 2011 ATSG Copyright 2011 ATSG Figure 64 Figure 65 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD CONT D Torque Converter Housing 6 Remove the transfer drive gear front lube seal as shown in Figure 66 7 Inspect the transfer drive gear front bearing assembly and the front differential assembly bearing race as shown in Figure 66 and replace as necessary 8 Inspect and clean all torque converter housing parts thoroughly and dry with compressed air replacing parts as necessary 9 Install a new transfer drive gear front lube seal as shown in Figure 67 10 Carefully install the transmission lube fluid tube with a plastic hammer using care not to bend the tube as shown in Figure 68 Cont d on page 32 801 TORQUE CONVERTER HOUSING ASSEMBLY 802 FRONT DIFFERENTIAL T
56. 539 REAR SUN GEAR ASSEMBLY 540 INPUT SHAFT THRUST BEARING ASSEMBLY 541 FRONT SUN GEAR RETAINING SNAP RING 542 FRONT PLANET CARRIER ASSEMBLY 543 FRONT PLANET CARRIER THRUST BEARING RACE 544 FRONT SUN GEAR 545 FRONT SUN GEAR THRUST BEARING ASSEMBLY 546 FRONT SUN GEAR THRUST BEARING RACE Copyright O 2011 ATSG Figure 152 AUTOMATIC TRANSMISSION SERVICE GROUP 4 ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly NOTE There is no need to remove the manual valve link retaining clip from the manual valve link unless the link retaining clip or manual valve is damaged Disassembled view of the manual valve in Figure 153 is used primarily for illustrative purposes 1 Remove the control valve body bolt using a 10 mm socket then remove the solenoid SLT SLS hold down bracket as shown in Figure 154 2 Remove the control valve body bolt using a 8 mm socket then remove the A T internal wire harness clip and the solenoid SLU hold down bracket as shown in Figure 154 3 Remove the solenoids SLS SLT and SLU as shown in Figure 154 Cont d on page 80 107 CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 Required 110 CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 Required 111 SOLENOID HOLD DOWN BRACKET Solenoid SLS SLT 115 LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR Blue 116 A T INTERNAL WIRE HARNESS CLIP 117 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET 136 TCC PRESSU
57. AND CONTROL VALVE SPRING ID PURPLE BA BAND CONTROL VALVE REAR CONTROL VALVE BODY COVER PLATE GASKET REAR CONTROL VALVE BODY COVER PLATE COVER PLATE ATTACHING BOLT 7 REQUIRED NO 2 REAR CONTROL VALVE BODY BORE PLUG RETAINER 2 3 2 X 5 X 15 mm ZND CLUTCH B2 CONTROL VALVE PLUG ZND CLUTCH B2 CONTROL VALVE SPRING ID NONE ZND CLUTCH B2 CONTROL VALVE TCC CHECK VALVE CHECK VALVE SPRING ID WHITE REVERSE INHIBIT CHECK BALL INNER BUSHING REVERSE INHIBIT CHECK BALL REVERSE INHIBIT CHECK BALL OUTER BUSHING LOCK UP CONTROL VALVE LOCK UP CONTROL VALVE PLUNGER LOCK UP CONTROL VALVE SPRING ID NONE LOCK UP CONTROL VALVE SLEEVE BORE PLUG RETAINER 1 3 2 X 5 X 21 2 mm Copyright O 2009 ATSG PGATSG PRESSURE RELIEF VALVE SPRING 4 WIRE DIAMETER 050 OUTSIDE DIAMETER 370 OVERALL LENGTH 1 128 COILS 5 COLOR ID NONE SOLENOID RELAY VALVE SPRING 25 WIRE DIAMETER 019 OUTSIDE DIAMETER 235 OVERALL LENGTH 755 COILS 9 COLOR ID RED U1 SHIFT VALVE SPRING 40 WIRE DIAMETER 032 OUTSIDE DIAMETER 400 OVERALL LENGTH 1 000 COILS 7 COLOR ID LT GREEN LOCK UP RELAY VALVE SPRING 51 WIRE DIAMETER 010 OUTSIDE DIAMETER 222 OVERALL LENGTH 0 927 COILS 12 COLOR ID RED SHIFT PRESSURE CONTROL VALVE SPRING 63 WIRE DIAMETER 025 OUTSIDE DIAMETER 229 OVERALL LENGTH 0 630 COILS 12 COLOR ID WHITE TCC CHECK VALVE SPRING 82 WIRE
58. ASE VALVE MANUAL VALVE COOLER BYPASS VALVE COOLER BYPASS VALVE SPRING ID NONE Figure 192 AUTOMATIC TRANSMISSION SERVICE GROUP TCC CHECK VALVE CHECK VALVE SPRING ID YELLOW REAR CONTROL VALVE BODY LOCK UP RELAY CONTROL VALVE SLEEVE LOCK UP RELAY CONTROL VALVE PLUNGER LOCK UP RELAY CONTROL VALVE SPRING ID RED LOCK UP RELAY CONTROL VALVE 1 2 REVERSE CLUTCH B5 CONTROL VALVE COVER PLATE ATTACHING BOLT 2 REQUIRED REAR CONTROL VALVE BODY COVER PLATE REAR CONTROL VALVE BODY COVER PLATE GASKET SECONDARY REGULATOR VALVE SECONDARY REGULATOR VALVE SPRING ID NONE SOLENOID SLT ACCUMULATOR PISTON SLT ACCUMULATOR OUTER SPRING ID ORANGE SLT ACCUMULATOR INNER SPRING ID ORANGE SHIFT PRESSURE CONTROL VALVE SLEEVE SHIFT PRESSURE CONTROL VALVE SPRING ID WHITE SHIFT PRESSURE CONTROL VALVE SHIFT PRESSURE CONTROL VALVE PLUNGER SHIFT PRESSURE CONTROL VALVE PLUNGER SLEEVE M2 SHIFT VALVE M2 SHIFT VALVE SPRING ID LT BLUE SHIFT PRESSURE RELAY VALVE SHIFT PRESSURE RELAY VALVE SPRING ID LT GREEN BA BAND CONTROL VALVE SPRING ID ORANGE BA BAND CONTROL VALVE REAR CONTROL VALVE BODY COVER PLATE GASKET REAR CONTROL VALVE BODY COVER PLATE COVER PLATE ATTACHING BOLT 7 REQUIRED NO 2 REAR CONTROL VALVE BODY BORE PLUG RETAINER 2 3 2 X 5 X 15 mm ZND CLUTCH B2 CONTROL VALVE PLUG ZND CLUTCH B2 CONTROL VALVE SPRING ID NO
59. B2 PISTON ASSEMBLY OUTER SEAL Copyright 2011 ATSG Figure 107 Copyright 2011 ATSG Figure 106 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 44 Install the Second Brake B2 Piston Return Spring Assembly into the pump assembly with the springs facing upward as shown in Figure 108 Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 45 Install the Second Brake B2 Apply Plate model dependant as shown in Figure 108 46 Install the Second Brake B2 Steel Plates and Lined Plates starting with a steel plate then alternating lined plates and steel plates ending with a lined plate as shown in Figure 108 47 Install the Second Brake B2 Backing Plate Selective as Shown in Figure 108 48 Install the Second Brake B2 Retaining Snap Ring as shown in Figure 108 49 Make sure the Retaining Snap Ring 1s fully seated and the ends not aligned with any of the cutouts as shown in Figure 109 Cont d on page 53 Make sure snap ring is fully seated and the ends are not aligned with any of the cutouts 0 3 E e 220 SECOND BRAKE B2 BACKING PLATE RETAINING SNAP RING 219 SECOND BRAKE B2 BACKING PLATE SELECTIVE 218 SECOND BRAKE B2 LINED PLATE ASSEMBLY AF23 5 REQUIRES 2 AF33 5 REQ
60. BLY EXPLODED VIEW 1D STAMP NONE 110 Y 111 Copyright O 2011 ATSG Figure 180 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 100 1 2 2 3 REVERSE SHIFT SOLENOID S3 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND CONNECTOR DARK GRAY CONTROL VALVE BODY BOLT M5 X 0 8 X 62 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 REQUIRED 3 4 4 5 SHIFT SOLENOID S4 CONNECTOR BLUE CONTROL VALVE BODY BOLT M5 X 0 8 X 50mm 2 REQUIRED REVERSE SHIFT SOLENOID S5 CONNECTOR BROWN SHIFT SOLENOID VALVE O RING SEAL 5 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 REQUIRED 2 3 3 4 SHIFT SOLENOID S2 CONNECTOR BLACK REVERSE 1ST SHIFT SOLENOID S1 CONNECTOR BLACK CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 REQUIRED SOLENOID HOLD DOWN BRACKET SOLENOID SLS SLT CONTROL VALVE BODY BOLT M5 X 0 8 X 20 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 16 mm 2 REQUIRED FRONT CONTROL VALVE BODY ASSEMBLY LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR BLUE 116 A T INTERNAL WIRE HARNESS CLIP 117 118 119 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE 120 121 122 123 124 125 126 127
61. BODY 203 OIL PUMP BODY TO PUMP STATOR SHAFT ASSEMBLY ALIGNMENT DOWEL PIN 2 REQUIRED 204 OIL PUMP DRIVEN GEAR 205 OIL PUMP DRIVE GEAR 206 AUTOMATIC TRANSMISSION OIL PUMP O RING SEAL 207 OIL PUMP PLATE Copyright O 2011 ATSG Figure 98 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 18 Clean all Oil Pump parts thoroughly and dry with compressed air 19 Using a feeler gage measure the clearance between the Pump Body and the gears as shown in a Figure 99 SST J 45000 Ze 20 Use the specifications shown in Figure 99 to SS determine if the pump gears and pump body are within clearance specifications 21 If excessive wear is indicated replace the pump assembly 22 Using SST J 45000 or similar seal removal tool remove the Oil Pump Body Seal as shown in Figure 100 23 Inspect the Oil Pump Body Converter Hub Bushing and replace as necessary 24 Using SST J 35582 or other similar seal installing tool install a new Oil Pump Body Seal as shown in Figure 101 Copyright O 2011 ATSG Figure 100 Cont d on page 49 SST J 35582 D Oil Pump Specifications Specification Drive Gear and Driven Gear to Pump Body Side Clearance 200 OIL PUMP BODY SEAL 202 OIL PUMP BODY Copyright 2011 ATSG Copyright 2011 ATSG Figure 99 Figure 101 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Oil Pump Assembly
62. BODY ASSEMBLY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND GASKETS Copyright O 2011 ATSG Figure 161 19 Remove the solenoid modulator valve oil filter the pressure relief valve and spring the two exhaust check valves and springs and the forward clutch C1 accumulator ball 412 as shown in Figure 162 Cont d on page 84 SOLENOID MODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRING FORWARD CLUTCH C1 ACCUMULATOR BALL 12 EXHAUST CHECK VALVE EXHAUST CHECK VALVE SPRING FRONT CONTROL VALVE BODY ASSEMBLY FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE FRONT CONTROL VALVE BODY SPACER PLATE TO MIDDLE CONTROL VALVE BODY GASKET Copyright O 2011 ATSG Figure 162 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 20 Lift and remove the rear control valve body spacer plate to rear control valve body gasket the rear control valve body spacer plate and the rear control valve body spacer plate to No 2 rear control valve body gasket as shown in Figure 163 21 Remove the TCC check valve the TCC check valve spring and the two accumulator check valves as shown in Figure 163 Cont d on page 85 20 ACCUMULATOR CHECK VALVE 81 TCC CHECK VALVE 82 TCC CHECK VALVE SPRING 124 REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY
63. CATION 1 269 1 645mm 0 050 0 065 4 ci eg Fu 7 Place a straight edge here on top of the bearing 1 sk E a Use a feeler gage and measure between the straight edge and M the case here to determine correct clearance measurement Le MEOE Figure 229 48 If measurement is not within specification choose a different transfer drive gear thrust washer from the chart in Figure 230 49I f the measurement is still not within specification using the largest thrust washer it will be necessary to remove the 1 2 Reverse internal gear and select a different 1 2 Reverse internal gear shim from the chart in Figure 230 50 Once the proper shims and washers are selected reinstall the transfer drive gear assembly and install the thrust washer and bearing as shown in Figure 228 Cont d on page 129 Front Differential Transfer Drive Gear Thrust Bearing Washer 264 1 2 Reverse Internal Gear Shim 596 Forward C1 and Direct C2 Clutch Housing Thrust Bearing Race 628 Identification n UE 0 043 in Copyright O 2011 ATSG Figure 230 128 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 51 Install the parking pawl spring guide pin as shown 59 Torque the 16 7 mm bolt to 10 Nm 89 in Ib as in Figure 231 shown in Figure 235 52 Install the parking pawl pin spring the guide sleeve spacer the parking pawl pin spring Cont d
64. CE GROUP TRANSAXLE DISASSEMBLY CONT D 23 Remove the six 10 mm control valve body assembly attaching bolts as shown in Figure 26 24 While holding the control valve body assembly carefully remove the manual valve shift detent lever from the manual valve link as shown in Figure 27 25 Remove the control valve body assembly and set aside for cleaning and component rebuild 26 Using a twisting motion carefully remove the transmission wiring harness assembly from the transmission as shown in Figure 28 27 Use care when removing the wiring harness to avoid damage to the connectors or the transmission oil temperature sensor 28 Remove and discard the transmission wiring harness assembly o ring Cont d on page 22 R ES i qw dir PR ou ce IR la ss Copyright 2011 ATSG Figure 28 W SN m Copyright O 2011 ATSG i Figure 29 Copyright 2011 ATSG Figure 31 Technical Service Information TRANSAXLE DISASSEMBLY CONT D 29 Remove and discard the two transmission case fluid passage seals as shown in Figure 29 30 Remove the seventeen torque converter housing attaching bolts as shown in Figure 30 31 Remove the eight pump assembly to case attaching bolts as shown in Figure 31 32 Using Universal Clamp Press J 45053 or other adequate pump pulling device attach the clamp and carefully remove the pump assembly from the case being careful not to damage the turbine shaft as shown in Fi
65. CONTROL VALVE BODY LOCK UP RELAY CONTROL VALVE SLEEVE LOCK UP RELAY CONTROL VALVE PLUNGER LOCK UP RELAY CONTROL VALVE SPRING ID RED LOCK UP RELAY CONTROL VALVE 1 2 REVERSE CLUTCH B5 CONTROL VALVE 53 1 2 REVERSE CLUTCH B5 CONTROL VALVE SPRING Figure 206 AUTOMATIC TRANSMISSION SERVICE GROUP 2005 AND LATER NISSAN MAXIMA UNITS ONLY COVER PLATE ATTACHING BOLT 2 REQUIRED REAR CONTROL VALVE BODY COVER PLATE REAR CONTROL VALVE BODY COVER PLATE GASKET SECONDARY REGULATOR VALVE SECONDARY REGULATOR VALVE SPRING ID NONE SOLENOID SLT ACCUMULATOR PISTON SLT ACCUMULATOR OUTER SPRING ID PINK SLT ACCUMULATOR INNER SPRING ID PINK SHIFT PRESSURE CONTROL VALVE SLEEVE SHIFT PRESSURE CONTROL VALVE SPRING ID WHITE SHIFT PRESSURE CONTROL VALVE SHIFT PRESSURE CONTROL VALVE PLUNGER SHIFT PRESSURE CONTROL VALVE PLUNGER SLEEVE M2 SHIFT VALVE M2 SHIFT VALVE SPRING ID LT BLUE SHIFT PRESSURE RELAY VALVE SHIFT PRESSURE RELAY VALVE SPRING ID LT GREEN B4 BAND CONTROL VALVE SPRING ID PURPLE B4 BAND CONTROL VALVE REAR CONTROL VALVE BODY COVER PLATE GASKET REAR CONTROL VALVE BODY COVER PLATE COVER PLATE ATTACHING BOLT 7 REQUIRED NO 2 REAR CONTROL VALVE BODY BORE PLUG RETAINER 2 3 2 X 5 X 15 mm 2ND CLUTCH B2 CONTROL VALVE PLUG 2ND CLUTCH B2 CONTROL VALVE SPRING ID NONE 2ND CLUTCH B2 CONTROL VALVE CHECK VALVE
66. CT CLUTCH C2 PISTON RETURN SPRING RETAINING SNAP RING 560 DIRECT CLUTCH C2 PISTON RETURN SPRING 561 DIRECT CLUTCH C2 PISTON INNER O RING SEAL 562 DIRECT CLUTCH C2 PISTON ASSEMBLY 550 FORWARD CLUTCH C1 RETAINING SNAP RING 563 DIRECT CLUTCH C2 PISTON OUTER O RING SEAL 551 FORWARD CLUTCH C1 BACKING PLATE SELECTIVE 564 FORWARD CLUTCH C1 PISTON INNER O RING SEAL 552 FORWARD CLUTCH C1 LINED PLATE 4 REQUIRED 565 FORWARD CLUTCH C1 PISTON ASSEMBLY 553 FORWARD CLUTCH C1 STEEL PLATE 4 REQUIRED 566 FORWARD CLUTCH C1 PISTON OUTER O RING SEAL 554 DIRECT CLUTCH C2 RETAINING SNAP RING 567 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY 555 DIRECT CLUTCH C2 BACKING PLATE SELECTIVE 568 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING 556 DIRECT CLUTCH C2 LINED PLATE 4 REQUIRED THRUST BEARING RACE SELECTIVE 557 DIRECT CLUTCH C2 STEEL PLATE 4 REQUIRED 569 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING THRUST BEARING ASSEMBLY 558 DIRECT CLUTCH C2 APPLY CUSHION PLATE 570 TURBINE SHAFT SEAL RING Copyright 2011 ATSG Figure 121 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG DIRECT CLUTCH C2 PISTON RETURN SPRING RETAINING SNAP RING DIRECT CLUTCH C2 PISTON RETURN SPRING DIRECT CLUTCH C2 PISTON INNER O RING SEAL DIRECT CLUTCH C2 PISTON ASSEMBLY DIRECT CLUTCH C2 PISTON OUTER O RING SEAL FORWARD CLUTCH C1 PISTON INNER O RING SEAL FORWAR
67. CTOR Dark Gray 101 CONTROL VALVE BODY BOLT M5 X 0 8 X 62 mm 1 Required 102 CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 Required 103 3 4 4 5 SHIFT SOLENOID S4 CONNECTOR Blue 105 REVERSE SHIFT SOLENOID S5 CONNECTOR Brown 106 SHIFT SOLENOID VALVE O RING SEAL 5 Required 107 CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 Required 108 2 3 3 4 SHIFT SOLENOID S2 CONNECTOR Black 109 REVERSE 1ST SHIFT SOLENOID S1 CONNECTOR Black Copyright 2011 ATSG Figure 176 57 Install the five solenoid control valve body attaching bolts as shown in Figure 177 Using a torque wrench and an 8 mm socket tighten the solenoid control valve body bolts and torque the bolts to 7 Nm 62 in Ib as shown in Figure 177 TORQUE CONTROL VALVE BODY ATTACHING BOLTS TO 7N m 62 n lb Copyright O 2011 ATSG Figure 177 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly 58 Install solenoids SLS SLT and SLU into the front control valve body as shown m Figure 178 59 Install the solenoid SLT SLS hold down bracket and the 10 mm bolt as shown in Figure 178 Install the solenoid SLU hold down bracket and the 60 A T internal wire harness clip then the control valve body bolt as shown in Figure 178 Tighten control valve body bolt 110 using a torque 61 wrench and a 10 mm socket and torque to 7 Nm 62 in Ib as shown in Figure 178 Tighten
68. D CLUTCH C1 PISTON ASSEMBLY FORWARD CLUTCH C1 PISTON OUTER O RING SEAL FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY Copyright 2011 ATSG Figure 122 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Forward C1 and Direct C2 Clutch Assembly 1 Disassemble the Forward C1 and Direct C2 Clutch Assembly using the diagram in Figure 121 as a guide 2 Clean all Forward C1 and Direct C2 Clutch parts with solvent and dry with compressed air 3 Inspect the clutch drum and pistons for wear or cracks and replace as necessary 4 Install a new Forward Clutch C1 Piston Outer O Ring Seal as shown in Figure 122 5 Install anew Forward Clutch C1 Piston Inner O Ring Seal as shown in Figure 122 6 Apply a small amount of Trans Jel to both piston O Ring seals then carefully install the Forward Clutch C1 Piston into the Forward C1 and Direct C2 Drum Housing by pressing downward as shown in Figure 122 7 Install a new Direct Clutch C2 Piston Outer O Ring Seal as shown in Figure 122 8 Install a new Direct Clutch C2 Piston Inner O Ring Seal as shown in Figure 122 9 Apply a small amount of Trans Jel to both piston o ring seals then carefully install the Direct Clutch C2 Piston into the Forward C1 and Direct C2 Drum Housing using a twisting motion as shown in Figure 122 10 Install the Direct Clutch C2 Piston Return Spring into the Direct Clutch C2 Piston as
69. DIAMETER 016 OUTSIDE DIAMETER 205 OVERALL LENGTH 0 468 COILS 7 COLOR ID WHITE Technical Service Information CONTROL VALVE BODY ASSEMBLY SPRING SPECIFICATIONS NO 1D STAMP VB SOLENOID MODULATOR VALVE SPRING 10 WIRE DIAMETER 043 OUTSIDE DIAMETER 315 OVERALL LENGTH 1 128 COILS 12 COLOR ID YELLOW PRESSURE REGULATOR VALVE SPRING 30 WIRE DIAMETER 047 OUTSIDE DIAMETER 525 OVERALL LENGTH 1 840 COILS 12 COLOR ID PURPLE B4 BAND RELEASE VALVE SPRING 41 WIRE DIAMETER 027 OUTSIDE DIAMETER 354 OVERALL LENGTH 0 90 COILS 8 COLOR ID BLUE SECONDARY REGULATOR VALVE SPRING 58 WIRE DIAMETER 035 OUTSIDE DIAMETER 375 OVERALL LENGTH 1 891 COILS 16 COLOR ID NONE M2 SHIFT VALVE SPRING 68 WIRE DIAMETER 027 OUTSIDE DIAMETER 325 OVERALL LENGTH 1 044 COILS 9 COLOR ID LT BLUE B2 CONTROL VALVE SPRING 79 WIRE DIAMETER 035 OUTSIDE DIAMETER 385 OVERALL LENGTH 1 368 COILS 9 COLOR ID NONE NEUTRAL RELAY VALVE SPRING 14 WIRE DIAMETER 026 OUTSIDE DIAMETER 324 OVERALL LENGTH 1 031 COILS 9 COLOR ID LT GREEN U2 SHIFT VALVE SPRING 34 WIRE DIAMETER 032 OUTSIDE DIAMETER 401 OVERALL LENGTH 1 000 COILS 7 COLOR ID LT GREEN COOLER BYPASS VALVE SPRING 45 WIRE DIAMETER 042 OUTSIDE DIAMETER 471 OVERALL LENGTH 680 COILS 6 COLOR ID NONE SLT ACCUMULATOR SPRING OUTER 60 WIRE DIAMETER 090 OUTSIDE DIAMETER 642 OVERALL LENG
70. DIAMETER 219 OVERALL LENGTH 0 830 COILS 11 COLOR ID YELLOW Figure 200 AUTOMATIC TRANSMISSION SERVICE GROUP B1 CONTROL VALVE SPRING 15 WIRE DIAMETER 022 OUTSIDE DIAMETER 233 OVERALL LENGTH 716 COILS 11 COLOR ID BLUE M1 SHIFT VALVE SPRING 37 WIRE DIAMETER 026 OUTSIDE DIAMETER 323 OVERALL LENGTH 1 040 COILS 9 COLOR ID LT GREEN TCC CHECK VALVE SPRING 47 WIRE DIAMETER 019 OUTSIDE DIAMETER 270 OVERALL LENGTH 654 COILS 11 COLOR ID YELLOW SLT ACCUMULATOR SPRING INNER 61 WIRE DIAMETER 063 OUTSIDE DIAMETER 409 OVERALL LENGTH 1 550 COILS 15 COLOR ID ORANGE B4 CONTROL VALVE SPRING 71 WIRE DIAMETER 032 OUTSIDE DIAMETER 293 OVERALL LENGTH 0 977 COILS 10 COLOR ID ORANGE EXHAUST CHECK VALVE SPRING 7 WIRE DIAMETER 010 OUTSIDE DIAMETER 173 OVERALL LENGTH 0 465 COILS 8 COLOR ID NONE Copyright O 2011 ATSG Technical Service Information PGATSG CONTROL VALVE BODY ASSEMBLY EXPLODED VIEW ID STAMP C Copyright 2011 ATSG Figure 201 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND 1 2 2 3 REVERSE SHIFT SOLENOID S3 CONNECTOR DARK GRAY CONTROL VALVE BODY BOLT M5 X 0 8 X 62 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 REQUIRED 3 4 4 5 SHIF
71. ECK VALVE CHECK VALVE SPRING ID YELLOW REAR CONTROL VALVE BODY LOCK UP RELAY CONTROL VALVE SLEEVE LOCK UP RELAY CONTROL VALVE PLUNGER LOCK UP RELAY CONTROL VALVE SPRING ID RED LOCK UP RELAY CONTROL VALVE 1 2 REVERSE CLUTCH B5 CONTROL VALVE 1 2 REVERSE CLUTCH B5 CONTROL VALVE SPRING 2005 AND LATER NISSAN MAXIMA UNITS ONLY COVER PLATE ATTACHING BOLT 2 REQUIRED REAR CONTROL VALVE BODY COVER PLATE REAR CONTROL VALVE BODY COVER PLATE GASKET SECONDARY REGULATOR VALVE SECONDARY REGULATOR VALVE SPRING ID NONE SOLENOID SLT ACCUMULATOR PISTON SLT ACCUMULATOR OUTER SPRING ID ORANGE SLT ACCUMULATOR INNER SPRING ID ORANGE SHIFT PRESSURE CONTROL VALVE SLEEVE SHIFT PRESSURE CONTROL VALVE SPRING ID WHITE SHIFT PRESSURE CONTROL VALVE SHIFT PRESSURE CONTROL VALVE PLUNGER SHIFT PRESSURE CONTROL VALVE PLUNGER SLEEVE M2 SHIFT VALVE M2 SHIFT VALVE SPRING ID LT BLUE SHIFT PRESSURE RELAY VALVE SHIFT PRESSURE RELAY VALVE SPRING ID LT GREEN BA BAND CONTROL VALVE SPRING ID ORANGE BA BAND CONTROL VALVE REAR CONTROL VALVE BODY COVER PLATE GASKET REAR CONTROL VALVE BODY COVER PLATE COVER PLATE ATTACHING BOLT 7 REQUIRED NO 2 REAR CONTROL VALVE BODY BORE PLUG RETAINER 2 3 2 X 5 X 15 mm ZND CLUTCH B2 CONTROL VALVE PLUG ZND CLUTCH B2 CONTROL VALVE SPRING ID NONE ZND CLUTCH B2 CONTROL VALVE CHECK VALVE
72. G 15 WIRE DIAMETER 022 OUTSIDE DIAMETER 233 OVERALL LENGTH 716 COILS 11 COLOR ID BLUE M1 SHIFT VALVE SPRING 37 WIRE DIAMETER 026 OUTSIDE DIAMETER 323 OVERALL LENGTH 1 022 COILS 9 COLOR ID LT GREEN TCC CHECK VALVE SPRING 47 WIRE DIAMETER 019 OUTSIDE DIAMETER 270 OVERALL LENGTH 654 COILS 11 COLOR ID YELLOW SLT ACCUMULATOR SPRING INNER 61 WIRE DIAMETER 063 OUTSIDE DIAMETER 413 OVERALL LENGTH 1 552 COILS 15 COLOR ID PINK B4 CONTROL VALVE SPRING 71 WIRE DIAMETER 032 OUTSIDE DIAMETER 293 OVERALL LENGTH 0 977 COILS 10 COLOR ID PURPLE B5 CONTROL VALVE SPRING 53 WIRE DIAMETER 027 OUTSIDE DIAMETER 315 OVERALL LENGTH 650 COILS 4 5 COLOR ID LT GREEN Copyright O 2011 ATSG ATSG ZU TD 235 236 GEAR TAPERED ROLLER BEARING ASSEMBLY 237 OUTPUT GEAR BEARING ASSEMBLY SPACER 238 OUTPUT GEAR BEARING RACE SLEEVE 239 OUTPUT GEAR TAPERED ROLLER BEARING ASSEMBLY 240 OUTPUT GEAR BEARING ASSEMBLY LOCKING NUT Copyright 2011 ATSG Figure 208 Technical Service Information TRANSAXLE FINAL ASSEMBLY Note It is not recommended to disassemble the Output Gear Assembly The exploded view diagram shown in Figure 208 is provided for illustration purposes only 1 Clean the output gear assembly with solvent and dry with compressed air 2 Inspect the output gear assembly for wear or damage
73. G ID NONE FORWARD CLUTCH C1 ACCUMULATOR BALL 12 EXHAUST CHECK VALVE 2 REQUIRED EXHAUST CHECK VALVE SPRING ID NONE 2 REQUIRED BORE PLUG RETAINER 4 3 2 X 5 X 10 mm BORE PLUG 4 SOLENOID MODULATOR VALVE SPRING ID YELLOW SOLENOID MODULATOR VALVE FORWARD CLUTCH C1 CONTROL VALVE NEUTRAL RELAY VALVE NEUTRAL RELAY VALVE SPRING ID LT GREEN 2ND COAST B1 CONTROL VALVE SPRING ID BLUE 2ND COAST B1 CONTROL VALVE MIDDLE CONTROL VALVE BODY SOLENOID OIL FILTER S2 S3 S4 SOLENOID OIL FILTER S1 S5 ACCUMULATOR CHECK VALVE BORE PLUG RETAINER 7 3 2 X 5 X 12 5 mm SOLENOID RELAY VALVE SLEEVE SOLENOID RELAY VALVE PLUNGER SOLENOID RELAY VALVE SOLENOID RELAY VALVE SPRING ID ORANGE REVERSE SHIFT CHECK BALL OUTER BUSHING REVERSE SHIFT CHECK BALL REVERSE SHIFT CHECK BALL INNER BUSHING PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE SPRING ID PURPLE PRESSURE REGULATOR VALVE PLUNGER PRESSURE REGULATOR VALVE SLEEVE U2 SHIFT VALVE U2 SHIFT VALVE SPRING ID LT GREEN BORE PLUG 3 M1 SHIFT VALVE M1 SHIFT VALVE SPRING ID LT GREEN M1 SHIFT VALVE BORE PLUG 1 U1 SHIFT VALVE U1 SHIFT VALVE SPRING ID LT GREEN BA RELEASE VALVE SPRING ID BLUE BA RELEASE VALVE MANUAL VALVE COOLER BYPASS VALVE COOLER BYPASS VALVE SPRING ID NONE Figure 199 AUTOMATIC TRANSMISSION SERVICE GROUP TCC CH
74. H IE DIRECT CLUTCH Lg 2 _ BA FL E SECOND COAST Fm Av L A AE BRAKE B1 Cs TT Will EW ME IL We gt lige LT C Rrr ME EE my Ok ELM ji la E A emm IE E gr M PUES Es S S 1 2 REVERSE VAL BRAKE SIE B5 E D i eg een ms lI li TA O LOT FE 4 5 CLUTCH CUT Nr meg SI C3 5 m Dee I MN Eloi ln o ad 3RD GEAR BRAKE BAND B4 Copyright 2011 ATSG Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT APPLICATION INFORMATION Refer to Figure 1 for a cutaway view of the A shift solenoid application chart is also provided in transmission indicating the internal component Figure 2 to aid the technician in diagnosis of this locations Refer to Figure 2 for the component transmission application chart which indicates individual component application for each gear range COMPONENT APPLICATION CHART SECOND SECOND SECOND COAST CLUTCH CLUTCH REVERSE RANGE GEAR BRAKE B2 wer rw evase we e fre TES I 1 1 EN eat ear Tea ETE CC CE A fem ere penas EE _ DRIVE Caere penas EE lelies wfe EE EEDEN Je
75. HIFT VALVE SPRING 24 SOLENOID RELAY VALVE 38 M1 SHIFT VALVE BORE PLUG 1 25 SOLENOID RELAY VALVE SPRING 39 U1 SHIFT VALVE 26 REVERSE SHIFT CHECK BALL OUTER BUSHING 40 U1 SHIFT VALVE SPRING 27 REVERSE SHIFT CHECK BALL 41 B4 RELEASE VALVE SPRING 28 REVERSE SHIFT CHECK BALL INNER BUSHING 42 BA RELEASE VALVE 29 PRESSURE REGULATOR VALVE 43 MANUAL VALVE 30 PRESSURE REGULATOR VALVE SPRING Copyright O 2011 ATSG Figure 166 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 32 Disassemble the middle control valve body using 35 Disassemble the front control valve body using the the diagram in Figure 166 as a guide Place all diagram in Figure 167 as a guide Place all valves valves and springs into an appropriate tray exactly and springs into an appropriate tray exactly as they as they were removed were removed 33 Clean all middle control valve body parts with 36 Clean all front control valve body parts with solvent and dry with compressed air solvent and dry with compressed air 34 Assemble the middle control valve body using the 37 Assemble the front control valve body using the diagram in Figure 166 as a guide Lubricate all diagram in Figure 167 as a guide Lubricate all valves with a small amount of ATF during valves with a small amount of ATF during installation installation Note pressure regulator valve sleeve is stepped and adjustable and
76. INION SHAFT 17 0 x 110 4 645 FRONT DIFFERENTIAL PINION SHAFT 2 REQUIRED 646 FRONT DIFFERENTIAL PINION SHAFT HOLDER Copyright O 2011 ATSG Figure 88 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT DIFFERENTIAL TRANSFER DRIVE GEAR ASSEMBLY EXPLODED VIEW 255 eus 254 256 255 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR BEARING RACE 2 REQUIRED 256 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR COUNTER GEAR BEARING SPACER 257 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR COUNTER DRIVEN GEAR 258 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR COUNTER DRIVEN GEAR RETAINING RING 259 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR CARRIER ASSEMBLY 260 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR 250 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR LOCK NUT RING GEAR RETAINING RING 251 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR 261 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR RING GEAR BEARING ASSEMBLY INNER RACE 262 4 5 CLUTCH HOUSING FLUID SEALING RINGS 252 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR DRIVE PINION 2 REQUIRED 253 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR 263 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR PARKING LOCK GEAR THRUST BEARING ASSEMBLY 254 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR 264 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR BEARING ASSEMBLY 2 REQUIRED THRUST BEARING WASHER Copyright O 2011 ATSG Figure 89 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information OIL PUMP ASSEMBLY SECOND COA
77. INTERNAL COMPONENT LOCATIO NS eeeeeeeee eese ee e ee e e te ete te ete ENER EN EN ENNEN EN NNN EN 3 i COMPONENTAND SHIFT SOLENOID APPLICATION CHAR T ccccccccccccccccccccccccccccccccccccccccccccccccccccccccecccccces 4 GENERAL DESCRIPTION AND DESCRIPTION OF GEAR RANGES cccccccccccccccccccccccccccccccccccccccccecccccccccccsces 5 d FLUID REQUIREMENT SANDLEVELCRECKING ee ee aee eee e ee e p er aa be ee se do doe EV eo ee de oe ed ed ee ed de 6 ELECTRICAL COMPONENT ccccccccccccccccccccsccccccccccccccccccccsccccccccccccccccccccccscccsccccceccccccccccccccccsccccceccccccccccccscsccccccecs 7 TYPICAL SATURN WIRING DIA GRA M ccccccccccccccccccccccccccccccccccccccccccccccccccccceccccccecccccceccccccececcccccccccccccccsceccccccecs 15 GM DIAGNOSTIC TROUBLE CODE LIS T ccccccoscoccccccccccccscsccccccccccccccccccccsccccccccceccccccccccccccccsesccccccccccccccccccsccccces 17 TRINN VM E ER AE MENN APR vive ee se de ee ee SI TT ER 19 COMPONENT REBUILD TORQUE CONVERTER HOUSINGASSEMBL Yi ees sesde gese seuss se ve ke ee ge ee eN ee oe ee Ge E Ya Re Si eN ee se ENS 29 TRANSMISSION CASE ASSEM B LY eee ee eee ee ee se se se se se ee see ee ee ee ee e ee ee ee ee EN ee KN EN ENNEN ee ee ee ee ee ee 33 FRONT DIFFERENTIULASSEMBLY SS SS SS SS SS SS KN SS Se ete tete REN EN Se ee ee ee ee ee so sos ee ee ee ee ee NNN EN EN NN ee KN ee ee 40
78. ISSION SERVICE GROUP ATSG ELECTRICAL COMPONENTS Cont d Reverse Shift Solenoid 555 The reverse shift solenoid is a normally closed N C ON OFF type solenoid controlled by the TCM Line fluid feeds the S5 signal fluid through orifice No 5 When the reverse shift solenoid is energized ON S5 signal fluid is allowed to exhaust through the base of the solenoid as shown in Figure 11 When the reverse shift solenoid is OFF S5 signal fluid is blocked from exhausting through the base of the solenoid creating S5 signal fluid pressure that acts on the shift pressure relay valve against spring force to move the valve into the applied position Line Pressure Control Solenoid SLT The line pressure control solenoid is a normally open 3 port solenoid and is a precision electronic pressure regulator that controls transaxle line pressure based on current flow through its coil windings This solenoid is Pulse Width Modulated PWM and operates at a fixed frequency of 300 Hz cycles per second and from 0 0 to 1 1 amps As current flow is increased the pressure control to throttle signal is decreased As current flow is decreased the pressure control to throttle signal is increased as shown in Figure 12 If a total electronic failure is encountered this solenoid will put line pressure to maximum pressure and will set DTC P0962 or P0963 in the TCM memory Transmission Adapt Function Solenoid SLT Programming within the TCM al
79. Internal Gear and Low Clutch Sprag F2 Assembly parts for wear and or damage replace as necessary 4 Install a new Inner O ring Seal and a new Outer O ring Seal on the Low and Reverse Brake B3 Piston as shown in Figure 143 5 Coat both O ring seals with a small amount of Trans Jel amp 510 LOW AND REVERSE BRAKE B3 PISTON INNER O RING SEAL 511 LOW AND REVERSE BRAKE B3 PISTON 512 LOW AND REVERSE BRAKE B3 PISTON OUTER O RING SEAL Copyright O 2011 ATSG Figure 143 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 6 Set the Low and Reverse Brake B3 Piston Assembly aside for final assembly 7 Install the Front Internal Gear Flange into the Front Internal Gear and Low Clutch Sprag F2 Assembly as shown in Figure 144 8 Install the Front Internal Gear Flange Retaining snap Ring into the Front Internal Gear and Low Clutch Sprag F2 Assembly as shown in Figure 144 9 Make sure the retaining snap ring 1s fully seated Cont d on page 74 25 FRONT INTERNAL GEAR AND LOW CLUTCH SPRAG F2 ASSEMBLY 527 FRONT INTERNAL GEAR FLANGE 528 FRONT INTERNAL GEAR FLANGE RETAINING SNAP RING Copyright O 2011 ATSG Figure 144 e ATSG Technical Service Information Low and Reverse Brake B3 Front Internal Gear and Low Clutch Sprag F2 Assembly 10 Coat the Front Internal Gear Thrust Bearing Assembly with a small amount of Trans Jel and place it onto the Front Internal Gear and Low Clutch Sp
80. METER 528 OVERALL LENGTH 1 859 COILS 12 COLOR ID PURPLE B4 BAND RELEASE VALVE SPRING 41 WIRE DIAMETER 027 OUTSIDE DIAMETER 354 OVERALL LENGTH 0 91 COILS 8 COLOR ID BLUE SECONDARY REGULATOR VALVE SPRING 58 WIRE DIAMETER 038 OUTSIDE DIAMETER 370 OVERALL LENGTH 1 857 COILS 16 COLOR ID NONE M2 SHIFT VALVE SPRING 68 WIRE DIAMETER 027 OUTSIDE DIAMETER 320 OVERALL LENGTH 1 044 COILS 9 COLOR ID LT BLUE TCC CHECK VALVE SPRING 82 WIRE DIAMETER 016 OUTSIDE DIAMETER 205 OVERALL LENGTH 0 462 COILS 7 COLOR ID WHITE NEUTRAL RELAY VALVE SPRING 14 WIRE DIAMETER 026 OUTSIDE DIAMETER 324 OVERALL LENGTH 1 026 COILS 9 COLOR ID LT GREEN U2 SHIFT VALVE SPRING 34 WIRE DIAMETER 032 OUTSIDE DIAMETER 394 OVERALL LENGTH 1 020 COILS 7 COLOR ID LT GREEN COOLER BYPASS VALVE SPRING 45 WIRE DIAMETER 042 OUTSIDE DIAMETER 471 OVERALL LENGTH 680 COILS 6 COLOR ID NONE SLT ACCUMULATOR SPRING OUTER 60 WIRE DIAMETER 088 OUTSIDE DIAMETER 632 OVERALL LENGTH 1 560 COILS 9 COLOR ID PINK SHIFT PRESSURE RELAY VALVE SPRING 70 WIRE DIAMETER 033 OUTSIDE DIAMETER 397 OVERALL LENGTH 1 045 COILS 7 COLOR ID LT GREEN LOCK UP CONTROL VALVE SPRING 88 WIRE DIAMETER 025 OUTSIDE DIAMETER 219 OVERALL LENGTH 0 839 COILS 11 COLOR ID NONE Figure 207 AUTOMATIC TRANSMISSION SERVICE GROUP B1 CONTROL VALVE SPRIN
81. NE ZND CLUTCH B2 CONTROL VALVE TCC CHECK VALVE CHECK VALVE SPRING ID WHITE REVERSE INHIBIT CHECK BALL INNER BUSHING REVERSE INHIBIT CHECK BALL REVERSE INHIBIT CHECK BALL OUTER BUSHING LOCK UP CONTROL VALVE LOCK UP CONTROL VALVE PLUNGER LOCK UP CONTROL VALVE SPRING ID YELLOW LOCK UP CONTROL VALVE SLEEVE BORE PLUG RETAINER 1 3 2 X 5 X 21 2 mm Copyright O 2011 ATSG 107 PGATSG PRESSURE RELIEF VALVE SPRING 4 WIRE DIAMETER 050 OUTSIDE DIAMETER 370 OVERALL LENGTH 1 128 COILS 5 COLOR ID NONE SOLENOID RELAY VALVE SPRING 25 WIRE DIAMETER 019 OUTSIDE DIAMETER 235 OVERALL LENGTH 793 COILS 9 COLOR ID ORANGE U1 SHIFT VALVE SPRING 40 WIRE DIAMETER 032 OUTSIDE DIAMETER 396 OVERALL LENGTH 1 028 COILS 7 COLOR ID LT GREEN LOCK UP RELAY VALVE SPRING 51 WIRE DIAMETER 022 OUTSIDE DIAMETER 231 OVERALL LENGTH 0 922 COILS 12 COLOR ID RED SHIFT PRESSURE CONTROL VALVE SPRING 63 WIRE DIAMETER 025 OUTSIDE DIAMETER 229 OVERALL LENGTH 0 620 COILS 12 COLOR ID WHITE B2 CONTROL VALVE SPRING 79 WIRE DIAMETER 034 OUTSIDE DIAMETER 385 OVERALL LENGTH 1 351 COILS 9 COLOR ID NONE Technical Service Information CONTROL VALVE BODY ASSEMBLY SPRING SPECIFICATIONS VALVE BODY ID STAMP 4 SOLENOID MODULATOR VALVE SPRING 10 WIRE DIAMETER 043 OUTSIDE DIAMETER 318 OVERALL LENGTH 1 128 COILS 12 COLOR ID YELLOW
82. NG SNAP RING SECOND COAST BRAKE B1 PISTON INNER SEAL SECOND COAST BRAKE B1 PISTON ASSEMBLY SECOND COAST BRAKE B1 PISTON OUTER SEAL Second Coast Brake B1 Piston Return Spring Assembly Second Coast Brake B1 Piston Return Spring Assembly Retaining Snap Ring Second Coast Brake B1 Clutch Hub Thrust Washer Assembly Second Coast Brake B1 Steel Plate Assembly 3 Required Second Coast Brake B1 Lined Plate Assembly 3 Required Second Coast Brake B1 Backing Plate Second Coast Brake B1 Backing Plate Retaining Snap Ring Automatic Transmission Oil Pump Cover Attaching Bolts M6 x 1 0 x 14 5 13 Required Automatic Transmission Oil Pump Cover Attaching Bolt M5 x 0 8 x 17 1 Required Copyright 2011 ATSG OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND SECOND BRAKE B2 ASSEMBLY SECOND COAST BRAKE B1 BACKING PLATE RETAINING SNAP RING SECOND COAST BRAKE B1 BACKING PLATE SECOND COAST BRAKE B1 LINED PLATE ASSEMBLY 3 REQUIRED SECOND COAST BRAKE B1 STEEL PLATE ASSEMBLY 3 REQUIRED Copyright 2011 ATSG Figure 92 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD CONT D Differential Assembly and Front Differential Transfer Drive Gear Assembly Note It is not recommended to disassemble the Differential assembly The exploded view diagram shown in Figure 88 is provided for illustration purposes only 1 Clean the differential
83. Neutral Position Switch assembly a DTC will be activated The DTC strategy may be different between the models you are working on PARK NEUTRAL POSITION SWITCH LOCATION Copyright 2011 ATSG Figure 8 AUTOMATIC TRANSMISSION SERVICE GROUP 2 e ATSG Technical Service Information PARK NEUTRAL POSITION SWITCH 70 WAY CONNECTOR IDENTIFICATION slee No Wire Color Number Circuit Function 3 Purple 6 OutToStmrterRelay 22 5 Gray 773 Transaxle Range C Signal To TCM ___ el Yellow 772 Transaxle Range B Signal To TCM 7 NetUsed 8 White 776 Transaxle Range Signal To TCM 9 Pink 239 Range Switch Power Fuse 104 From Underhood Fuse Block Tan White Transaxle Range A Signal To TCM 7 7 7 9 4 73 72 76 9 71 Transaxle Range Switch Vehicle Harness Transaxle Range Switch Connector Face View Connector Face View RANGE CIRCUIT INDICATOR Pak 1 O o 1 Reverse 1 1 0 0 Low 1 Closed Resistance lt 10 ohms 2 Open Resistance gt 100k ohms Copyright 2011 ATSG Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS ELECTRICAL COMPONENTS Cont d Shift Solenoids Technical Service Information The AF23 33 5 uses five electromagnetic shift solenoids to control up shifts and down shifts in all forward ranges and are controlled by the TCM They work together in a combination of ON and OFF sequences to control the v
84. ODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRING ID NONE FORWARD CLUTCH C1 ACCUMULATOR BALL 12 BORE PLUG RETAINER 4 3 2 X 5 X 10 mm BORE PLUG 4 SOLENOID MODULATOR VALVE SPRING ID YELLOW SOLENOID MODULATOR VALVE FORWARD CLUTCH C1 CONTROL VALVE NEUTRAL RELAY VALVE NEUTRAL RELAY VALVE SPRING ID LT GREEN 2ND COAST B1 CONTROL VALVE SPRING ID BLUE 2ND COAST B1 CONTROL VALVE MIDDLE CONTROL VALVE BODY SOLENOID OIL FILTER S2 S3 S4 SOLENOID OIL FILTER S1 S5 ACCUMULATOR CHECK VALVE BORE PLUG RETAINER 7 3 2 X 5 X 12 5 mm SOLENOID RELAY VALVE SLEEVE SOLENOID RELAY VALVE PLUNGER SOLENOID RELAY VALVE SOLENOID RELAY VALVE SPRING ID RED REVERSE SHIFT CHECK BALL OUTER BUSHING REVERSE SHIFT CHECK BALL REVERSE SHIFT CHECK BALL INNER BUSHING PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE SPRING ID PURPLE PRESSURE REGULATOR VALVE PLUNGER PRESSURE REGULATOR VALVE SLEEVE U2 SHIFT VALVE U2 SHIFT VALVE SPRING ID LT GREEN BORE PLUG 3 M1 SHIFT VALVE M1 SHIFT VALVE SPRING ID LT GREEN M1 SHIFT VALVE BORE PLUG 1 U1 SHIFT VALVE U1 SHIFT VALVE SPRING ID LT GREEN BA RELEASE VALVE SPRING ID BLUE BA RELEASE VALVE MANUAL VALVE COOLER BYPASS VALVE COOLER BYPASS VALVE SPRING ID NONE 53 TCC CHECK VALVE CHECK VALVE SPRING ID YELLOW REAR
85. ODY BOLT M5 X 0 8 X 62 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 REQUIRED 3 4 4 5 SHIFT SOLENOID S4 CONNECTOR BLUE CONTROL VALVE BODY BOLT M5 X 0 8 X 50mm 2 REQUIRED REVERSE SHIFT SOLENOID S5 CONNECTOR BROWN SHIFT SOLENOID VALVE O RING SEAL 5 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 REQUIRED 2 3 3 4 SHIFT SOLENOID S2 CONNECTOR BLACK REVERSE 1ST SHIFT SOLENOID S1 CONNECTOR BLACK CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 REQUIRED SOLENOID HOLD DOWN BRACKET SOLENOID SLS SLT CONTROL VALVE BODY BOLT M5 X 0 8 X 20 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 16 mm 2 REQUIRED FRONT CONTROL VALVE BODY ASSEMBLY LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR BLUE 116 A T INTERNAL WIRE HARNESS CLIP 117 118 119 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE 120 121 122 FRONT CONTROL VALVE BODY SPACER PLATE MIDDLE CONTROL VALVE BODY GASKET MIDDLE CONTROL VALVE BODY ASSEMBLY MIDDLE CONTROL VALVE BODY ASSEMBLY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND BONDED GASKETS 123 REAR CONTROL VALVE BODY ASSEMBLY 124 REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY ASSEMBLY GASKET 125 REAR CONTROL VALVE BODY SPACER PLATE 126 REAR CONTROL VALVE BODY SPACER PLATE
86. OW Figure 193 AUTOMATIC TRANSMISSION SERVICE GROUP B1 CONTROL VALVE SPRING 15 WIRE DIAMETER 022 OUTSIDE DIAMETER 233 OVERALL LENGTH 716 COILS 11 COLOR ID BLUE M1 SHIFT VALVE SPRING 37 WIRE DIAMETER 026 OUTSIDE DIAMETER 323 OVERALL LENGTH 1 021 COILS 9 COLOR ID LT GREEN TCC CHECK VALVE SPRING 47 WIRE DIAMETER 019 OUTSIDE DIAMETER 270 OVERALL LENGTH 654 COILS 11 COLOR ID YELLOW SLT ACCUMULATOR SPRING INNER 61 WIRE DIAMETER 063 OUTSIDE DIAMETER 409 OVERALL LENGTH 1 554 COILS 15 COLOR ID ORANGE B4 CONTROL VALVE SPRING 71 WIRE DIAMETER 033 OUTSIDE DIAMETER 292 OVERALL LENGTH 0 977 COILS 10 COLOR ID ORANGE EXHAUST CHECK VALVE SPRING 7 WIRE DIAMETER 010 OUTSIDE DIAMETER 173 OVERALL LENGTH 0 465 COILS 8 COLOR ID NONE Copyright O 2011 ATSG PAATSG Technical Service Information CONTROL VALVE BODY ASSEMBLY EXPLODED VIEW ID STAMP B Copyright 2011 ATSG Figure 194 AUTOMATIC TRANSMISSION SERVICE GROUP 109 ATSG 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND 1 2 2 3 REVERSE SHIFT SOLENOID S3 CONNECTOR DARK GRAY CONTROL VALVE BODY BOLT M5 X 0 8 X 62 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 REQUIRED 3 4 4 5 SHIFT SOLENOID S4 CONNECTOR BLUE CONTROL VALVE BODY BOLT M5 X 0 8 X
87. Position Range Obtained I 4 Bl c p ela B5 Fail Safe D h lorlor or or or og og on Mode 1 2 fF on or og og or R Reverse Of of or og on og og og Fail Safe D a Jo or on on og og og og Consuet 2nd for or on or og og og or twis R Reverse anf Of On og On og og og Fail Safe D or or or or or og og og Modes and Off On On Of og og R Reverse op op off og on og og og Fail Safe D hs of or or or on og og og Mode 4 OR Reverse orf off og og og or og Fail Safe D mm or or or or or of og og Mode 3 OR Reverse off off onr orf on og og of 156 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES OPERATING MODES NISSAN FAIL SAFE MODES continued ode osition ange Obtaine A B C D E use 1 i or or or or or Modes t m4 Jor or on or or aa a forforforforfor Mode zw Jon On og or og ox ewo orar on on or or or or Falsa D 5m Of on of or or or og or Consun LL zm Jor on on or or og og og ts Reverse Off On og og On og og og Fasaje D 4m Of of or on or og og or Consult I Reverse o o Of og om og og or Falsa D _ _ Of Of Of on or or og or Consun 5 4 Jor op on on or og
88. R SERVICE GMISAABISATURN S 2 SOLENOID NORMALLY OPEN N O Can be identified by the domed top Figure 261 NISSAN VOLVO S 2 SOLENOID NORMALLY CLOSED Can be identified by the flat top Figure 262 142 AUTOMATIC TRANSMISSION SERVICE GROUP ARTSU Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE SHIFT SOLENOID SEQUENCE CHART GM SAAB SATURN oy or or gt Low ow de oy or of gt om or or om or or ME N ME O om gt or or fom or NISSAN VOLVO D or or or Figure 263 AUTOMATIC TRANSMISSION SERVICE GROUP 143 e ATSG Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE SLS SLT SOLENOID RETAINING BRACKET 1 D These Ist and 2nd design brackets are used with the early short Rare early Ist design bracket SLS SLT solenoids only The narrow end goes up Slightly scalloped edge The 2nd design bracket had The wider end goes down more metal added for strength The 3rd design bracket is used for all long SLS SLT solenoids Connectors may face up or down The narrow end goes up The wider end with the backwards L goes down Figure 264 144 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE SLS SLT SOLENOID I D This round hole can be used to quickly I D the
89. R and 1 2 3 4 5 or 5 4 3 2 1 If the accelerator is depressed rapidly this control establishes the upper limit value of engine torque and avoids engine flare at 2 3 3 2 3 4 4 3 and 4 2 of a clutch to clutch shift AUTOMATIC TRANSMISSION SERVICE GROUP 155 e ATSG Technical Service Information AW55 50 SN SERIES OPERATING MODES SMOOTH LOCK UP CONTROL When shifting from the lock up released state to the lock up applied state current output to pressure control solenoid C 15 controlled by the TCM When shifting to the lock up applied state the converter clutch is temporarily set to the half clutched state to reduce the shock Half Clutched State Current output from the TCM to pressure control solenoid C 1s varied to steadily increase pressure control solenoid C pressure The lock up pressure gradually rises and while the converter clutch piston 15 put into half clutched status the converter clutch piston operating pressure is increased and the coupling is completed smoothly Slip Lock Up Control In the slip mode the pressure control solenoid C current 1s controlled by the TCM to put it into the half clutched state This absorbs engine torque fluctuation and lock up operates at low speed This raises fuel efficiency for 4th and Sth gears at both low speed and when the accelerator has a low degree ofthrottle opening NISSAN FAIL SAFE MODES i Pressure Control Fail Safe Shift Lever Actual Gear Shift Solenoid Status Solenoid Status Mode
90. RANSFER DRIVE GEAR FRONT LUBE TEFLON SEAL Copyright 2011 ATSG Figure 67 802 FRONT DIFFERENTIAL TRANSFER DRIVE GEAR FRONT LUBE TEFLON SEAL 801 TORQUE CONVERTER HOUSING ASSEMBLY 816 DIFFERENTIAL TRANSFER DRIVE GEAR 804 TRANSMISSION LUBE FLUID TUBE FRONT BEARING ASSEMBLY 817 FRONT DIFFERENTIAL ASSEMBLY BEARING RACE Copyright 2011 ATSG Copyright 2011 ATSG Figure 66 Figure 68 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG COMPONENT REBUILD CONT D Torque Converter Housing 11 Install the automatic transmission fluid baffle as shown in Figure 69 12 Install and hand tighten the lube fluid tube hold down bracket and the hold down bracket retaining bolt as shown in Figure 69 13 Install and hand tighten the three automatic transmission fluid baffle retaining bolts as shown in Figure 69 14 Using a torque wrench tighten the lube fluid tube hold down bracket retaining bolt and torque the bolt to 5 N m 44 in Ib as shown in Figure 70 15 Using a torque wrench tighten the three automatic transmission fluid baffle retaining bolts and torque the bolts to 5 N m 44 in Ib as Shown in Figure 70 16 Using a plastic hammer tapping evenly install the torque converter housing axle seal as shown in Figure 71 803 AUTOMATIC TRANSMISSION FLUID BAFFLE 805 LUBE FLUID TUBE HOLD DOWN BRACKET 806 LUBE FLUID TUBE BRACKET RETAINING BOLT M6 X 1 0 X 14 1 REQUIRED 807 TRANSMISSION FLUID BAFFLE RETAINING BOLT M6 X
91. RE CONTROL SOLENOID SLU CONNECTOR Black 137 SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR Green 133 MANUAL VALVE LINK 134 MANUAL VALVE 135 MANUAL VALVE LINK RETAINING CLIP 139 CONTROL VALVE BODY ASSEMBLY Copyright 2011 ATSG Copyright 2011 ATSG Figure 153 Figure 154 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 4 Remove the control valve body bolts using a 8 mm 6 Remove the 7 remaining control valve body bolts socket then remove the five solenoids S1 S2 S3 using an 8 mm socket as shown in Figure 156 S4 and S5 as shown in Figure 155 5 Remove and discard the shift solenoid valve o ring Cont d on page 81 seals as shown in Figure 155 100 1 2 2 3 REVERSE SHIFT SOLENOID S3 CONNECTOR Dark Gray 101 CONTROL VALVE BODY BOLT M5 X 0 8 X 62 mm 1 Required 102 CONTROL VALVE BODY BOLT M5 X 0 8 X 28 mm 3 Required 103 3 4 4 5 SHIFT SOLENOID S4 CONNECTOR Blue 105 REVERSE SHIFT SOLENOID S5 CONNECTOR Brown 106 SHIFT SOLENOID VALVE O RING SEAL 5 Required 104 CONTROL VALVE BODY BOLT 107 CONTROL VALVE BODY BOLT M5 X 0 8 X 50 mm 2 Required M5 X 0 8 X 10 mm 2 Required 112 CONTROL VALVE BODY BOLT 108 2 3 3 4 SHIFT SOLENOID S2 M5 X 0 8 X 20 mm 4 Required CONNECTOR Black 113 CONTROL VALVE BODY BOLT REVERSE 1ST SHIFT SOLENOID 51 M5 X 0 8 X 16 mm 2 Required CONNECTOR Black
92. RUM HOUSING THRUST BEARING RACE ASSEMBLY Copyright O 2011 ATSG Figure 134 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Automatic Transmission Rear Cover 1 2 Reverse Brake B5 Housing Assembly Cont d 28 Using SST J 45166 and J 45200 or other adeguate dial indicator set the dial indicator base onto the Forward Clutch C1 Accumulator and attach with the previously omitted bolt 29 Put the dial indicator on the 1 2 Reverse Brake B5 Piston and set the dial indicator to a Zero reading as shown in Figure 135 Caution When using compressed air wear safety glasses in order to help prevent injury to the eyes Checking 7 2 Reverse Brake 85 Clutch Clearance Carefully apply air here for 1 2 Reverse Brake B5 Clutch Assembly Specifications Copyright 2011 ATSG Figure 135 Available 1 2 Reverse Brake B5 Backing Plate Thicknesses Technical Service Information 30 Carefully apply a small amount of compressed air into the 1 2 Reverse Brake B5 apply port and check for proper piston stroke as shown in Figure 135 31 When applying the compressed air make sure piston moves smoothly in the bore 32 If piston stroke is not within the specifications listed in the chart in Figure 135 select a different size 1 2 Reverse Brake B5 Backing Plate from the available thicknesses listed 33 Remove the dial indicator assembly and install the remaining bolt into the Forward Clutch C1 Accumulator Housing 34 Using a
93. SIDE DIAMETER 315 OVERALL LENGTH 1 113 COILS 12 COLOR ID YELLOW PRESSURE REGULATOR VALVE SPRING 30 WIRE DIAMETER 047 OUTSIDE DIAMETER 525 OVERALL LENGTH 1 890 COILS12 COLOR ID PURPLE B4 BAND RELEASE VALVE SPRING 41 WIRE DIAMETER 027 OUTSIDE DIAMETER 354 OVERALL LENGTH 0 92 COILS 8 COLOR ID BLUE SECONDARY REGULATOR VALVE SPRING 58 WIRE DIAMETER 038 OUTSIDE DIAMETER 375 OVERALL LENGTH 1 860 COILS 16 COLOR ID NONE M2 SHIFT VALVE SPRING 68 WIRE DIAMETER 027 OUTSIDE DIAMETER 320 OVERALL LENGTH 1 044 COILS 9 COLOR ID LT BLUE TCC CHECK VALVE SPRING 82 WIRE DIAMETER 016 OUTSIDE DIAMETER 205 OVERALL LENGTH 0 468 COILS 7 COLOR ID WHITE NEUTRAL RELAY VALVE SPRING 14 WIRE DIAMETER 026 OUTSIDE DIAMETER 324 OVERALL LENGTH 1 021 COILS 9 COLOR ID LT GREEN U2 SHIFT VALVE SPRING 34 WIRE DIAMETER 032 OUTSIDE DIAMETER 394 OVERALL LENGTH 1 035 COILS 7 COLOR ID LT GREEN COOLER BYPASS VALVE SPRING 45 WIRE DIAMETER 042 OUTSIDE DIAMETER 471 OVERALL LENGTH 680 COILS 6 COLOR ID NONE SLT ACCUMULATOR SPRING OUTER 60 WIRE DIAMETER 088 OUTSIDE DIAMETER 642 OVERALL LENGTH 1 560 COILS 9 COLOR ID ORANGE SHIFT PRESSURE RELAY VALVE SPRING 70 WIRE DIAMETER 033 OUTSIDE DIAMETER 397 OVERALL LENGTH 1 045 COILS 7 COLOR ID LT GREEN LOCK UP CONTROL VALVE SPRING 88 WIRE DIAMETER 025 OUTSIDE
94. SPECIFICATIONS 3RD GEAR SERVO B4 SOLENOID SLT 4 5 CLUTCH C3 FORWARD CLUTCH C1 1 2 REVERSE CLUTCH B5 SR CLUTCH C3 DIRECT LUBRICATION CLUTCH C2 Ee PRESSURE CLUTCH C1 LUBRICATION SOLENOID SLT C1 C2 C3 B4 B5 PRESSURE PRESSURE PRESSURE Cold temperature 0 deg F 48 57 psi idle Drive Range no load above 10 psi Approx 5 psi idle no load 186 202 psi Drive Range WOT max load Operating temp 150 deg F i 73 89 psi idle Rev Range no load approx 5 psi in D 8 psi in R Approx 80 psi WOT max load 248 287 psi Rev Range WOT max load Copyright 2011 ATSG Figure 277 162 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information CASE PASSAGE IDENTIFICATION AIR PRESSURE TEST PORTS 3RD GEAR SERVO B4 THROTTLE SIGNAL SLT ilte e GZ CLUTCH B5 RELEASE LO FORWARD Lee dur CLUTCH C1 2ND COAST CLUTCH B1 LOW REVERSE CLUTCH LUBE ST O T B arr mm C2 AND ir re LUBE jie CLUTCH B2 Ko 4 5 CLUTCH C3 149 el pa O LUBE v ro mauu RETURN LUBE mas Copyright 2011 ATSG Figure 278 AUTOMATIC TRANSMISSION SERVICE GROUP 163 PAATSG Technical Service Information DIAGNOSTIC TROUBLE CODES DTC S VOLVO DIAGNOSTIC TROUBLE OEM CODES CODE DTC DESCRIPTION P0218 TCM 0046 Oil Temperature Oil Temperature Too High Gen TCM 009A Battery Voltage Voltage Signal Too Low P
95. SSEMBLY CONTROL VALVE BODY BOLT M5 X 0 8 X 76 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 40 mm 1 REQUIRED CONTROL VALVE BODY ASSEMBLY PRESSURE TEST PORT BOLT M6 X 1 0 X 12 mm 1 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 35 mm 2 REQUIRED MANUAL VALVE LINK MANUAL VALVE MANUAL VALVE LINK RETAINING CLIP TCC PRESSURE CONTROL SOLENOID SLU CONNECTOR BLACK SHIFT PRESSURE CONTROL SOLENOID SLS CONNECTOR GREEN Copyright 2011 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT CONTROL VALVE BODY D 10 amp 3 Y mm IL DU S p S 2 12 lt Q S 16 gt Set N 9 Copyright O 2011 ATSG Figure 196 AUTOMATIC TRANSMISSION SERVICE GROUP 111 Technical Service Information ATSG MIDDLE CONTROL VALVE BODY DANNY DY Me 97 Ls E CHER y 7 E AG 503 eg JEN GJ 8 V Copyright 2011 ATSG Figure 197 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information REAR CONTROL VALVE BODY NO 2 REAR CONTROL VALVE BODY 55 Copyright 2011 ATSG Figure 198 AUTOMATIC TRANSMISSION SERVICE GROUP 113 PAATSG 0 00 N Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND FRONT CONTROL VALVE BODY SOLENOID MODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRIN
96. ST BRAKE 87 AND SECOND BRAKE 82 ASSEMBLY EXPLODED VIEW me 231 D 232 D Copyright O 2011 ATSG Figure 90 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 200 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 Technical Service Information OIL PUMP ASSEMBLY SECOND COAST BRAKE 87 AND SECOND BRAKE 82 ASSEMBLY LEGEND AUTOMATIC TRANSMISSION OIL PUMP BODY SEAL ASSEMBLY OIL PUMP BODY OIL PUMP BODY TO PUMP STATOR SHAFT ASSEMBLY ALIGNMENT DOWEL PIN OIL PUMP DRIVEN GEAR OIL PUMP DRIVE GEAR AUTOMATIC TRANSMISSION OIL PUMP O RING SEAL OIL PUMP PLATE OIL PUMP STATOR SHAFT ASSEMBLY SECOND BRAKE B2 PISTON OUTER SEAL SECOND BRAKE B2 PISTON ASSEMBLY SECOND BRAKE B2 PISTON SLEEVE OUTER SEAL SECOND BRAKE B2 PISTON SLEEVE SECOND BRAKE B2 PISTON SLEEVE INNER SEAL SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY RETAINING SNAP RING SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY SECOND BRAKE B2 APPLY PLATE AF23 5 UNITS ONLY 217 SECOND BRAKE B2 STEEL PLATE ASSEMBLY AF23 5 REQUIRES 3 AF33 5 REQUIRES 4 Figure 91 AUTOMATIC TRANSMISSION SERVICE GROUP 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 SECOND BRAKE 2 LINED PLATE ASSEMBLY AF23 5 REQUIRES 2 AF33 5 REQUIRES 4 SECOND BRAKE B2 BACKING PLATE SELECTIVE SECOND BRAKE B2 BACKING PLATE RETAINI
97. Second Coast Brake B1 and Second Brake B2 Assembly Cont d 25 Apply a small amount of Automatic Transmission Fluid ATF to the surface ofthe pump body 26 Install the Oil Pump Driven Gear into the Pump Body as shown in Figure 102 27 Install the Oil Pump Drive Gear into the Pump Body as shown in Figure 102 NOTE Check the index marks on the pump gears as they are being installed The index mark on the Driven Gear faces Up The index mark on the Drive Gear faces Down Bottom view of Pump Drive Gear Index Mark 202 OIL PUMP BODY 203 OIL PUMP BODY TO PUMP STATOR SHAFT ASSEMBLY ALIGNMENT DOWEL PIN 2 REQUIRED 204 OIL PUMP DRIVEN GEAR 205 OIL PUMP DRIVE GEAR Copyright O 2011 ATSG Figure 102 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 28 Install a new Pump O Ring Seal onto the Oil Pump Body as shown in Figure 103 29 Coat the O Ring Seal with a small amount of Trans Jel 30 Install the Alignment Dowels and the Oil Pump Plate onto the Oil Pump Body carefully aligning the holes in the Oil Pump Plate onto the Alignment Dowel Pins in the Pump Body as shown in Figure 103 Cont d on page 50 oe 203 AFI 202 OIL PUMP BODY 203 OIL PUMP BODY TO PUMP STATOR SHAFT ASSEMBLY ALIGNMENT DOWEL PIN 2 REQUIRED 206 AUTOMATIC TRANSMISSION OIL PUMP O RING SEAL 207 OIL PUMP PLATE Copyright 2011 ATSG Figure 103 ATSG Oil Pump Assembly Second Coast Brake B1 and Se
98. T 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY Copyright O 2011 ATSG Figure 170 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 44 While holding the separator plate and gaskets to the No 2 rear control valve body flip the valve body over and align the bolt holes in the No 2 rear control valve body with the bolt holes in the rear control valve body as shown in Figure 171 45 Install the five control valve body attaching bolts and hand tighten only as shown in Figure 171 Cont d on page 91 123 REAR CONTROL VALVE BODY ASSEMBLY 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY 128 CONTROL VALVE BODY BOLT M5 X 0 8 X 76 mm 1 Required 129 CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 mm 4 Required Copyright 2011 ATSG Figure 171 ARTS COMPONENT REBUILD Control Valve Body Assembly Cont d 46 Install the S2 S3 and S4 solenoid oil filters into the middle control valve body as shown in Figure 168 47 Install the SI and S5 oil filter into the middle control valve body as shown in Figure 172 48 Install the two accumulator check valves into the middle control valve body and then install the control valve body attaching bolt and hand tighten only as shown in Figure 172 49 Install the solenoid modulator valve filter into the front control valve body as shown in Figure 173 50 Install the pressure relief valve spring and the pressure relief valve into the front control valve body as shown in Figure 173
99. T SOLENOID S4 CONNECTOR BLUE CONTROL VALVE BODY BOLT M5 X 0 8 X 50mm 2 REQUIRED REVERSE SHIFT SOLENOID S5 CONNECTOR BROWN SHIFT SOLENOID VALVE O RING SEAL 5 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 10 mm 2 REQUIRED 2 3 3 4 SHIFT SOLENOID S2 CONNECTOR BLACK REVERSE 1ST SHIFT SOLENOID S1 CONNECTOR BLACK CONTROL VALVE BODY BOLT M5 X 0 8 X 13 mm 1 REQUIRED SOLENOID HOLD DOWN BRACKET SOLENOID SLS SLT CONTROL VALVE BODY BOLT M5 X 0 8 X 20 mm 4 REQUIRED CONTROL VALVE BODY BOLT M5 X 0 8 X 16 mm 2 REQUIRED FRONT CONTROL VALVE BODY ASSEMBLY LINE PRESSURE CONTROL SOLENOID SLT CONNECTOR BLUE 116 A T INTERNAL WIRE HARNESS CLIP 117 118 119 TCC PRESSURE CONTROL SOLENOID SLU RETAINING BRACKET FRONT CONTROL VALVE BODY SPACER PLATE TO FRONT CONTROL VALVE BODY GASKET FRONT CONTROL VALVE BODY SPACER PLATE 120 121 122 FRONT CONTROL VALVE BODY SPACER PLATE MIDDLE CONTROL VALVE BODY GASKET MIDDLE CONTROL VALVE BODY ASSEMBLY MIDDLE CONTROL VALVE BODY ASSEMBLY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND BONDED GASKETS 123 REAR CONTROL VALVE BODY ASSEMBLY 124 REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY ASSEMBLY GASKET 125 REAR CONTROL VALVE BODY SPACER PLATE 126 REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKET 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY 128 CONTROL VALVE BODY BOLT
100. TH 1 550 COILS 9 COLOR ID PINK SHIFT PRESSURE RELAY VALVE SPRING 70 WIRE DIAMETER 033 OUTSIDE DIAMETER 400 OVERALL LENGTH 0 996 COILS 7 COLOR ID LT GREEN LOCK UP CONTROL VALVE SPRING 88 WIRE DIAMETER 027 OUTSIDE DIAMETER 218 OVERALL LENGTH 0 830 COILS 11 COLOR ID NONE Figure 186 AUTOMATIC TRANSMISSION SERVICE GROUP B1 CONTROL VALVE SPRING 15 WIRE DIAMETER 022 OUTSIDE DIAMETER 233 OVERALL LENGTH 725 COILS 11 COLOR ID BLUE M1 SHIFT VALVE SPRING 37 WIRE DIAMETER 026 OUTSIDE DIAMETER 323 OVERALL LENGTH 1 040 COILS 9 COLOR ID LT GREEN TCC CHECK VALVE SPRING 47 WIRE DIAMETER 019 OUTSIDE DIAMETER 270 OVERALL LENGTH 654 COILS 11 COLOR ID YELLOW SLT ACCUMULATOR SPRING INNER 61 WIRE DIAMETER 063 OUTSIDE DIAMETER 413 OVERALL LENGTH 1 546 COILS 15 COLOR ID PINK B4 CONTROL VALVE SPRING 71 WIRE DIAMETER 032 OUTSIDE DIAMETER 299 OVERALL LENGTH 1 010 COILS 10 COLOR ID PURPLE Copyright O 2009 ATSG PAATSG Technical Service Information CONTROL VALVE BODY ASSEMBLY EXPLODED VIEW ID STAMP d Copyright 2011 ATSG Figure 187 102 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Technical Service Information CONTROL VALVE BODY ASSEMBLY LEGEND 1 2 2 3 REVERSE SHIFT SOLENOID S3 CONNECTOR DARK GRAY CONTROL VALVE B
101. TIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 11 While pulling upward on the piston assemblies carefully apply compressed air into the passage for the Second Brake B2 in the pump assembly and remove the Second Brake B2 Piston Assembly and the Second Brake B2 Piston Sleeve Assembly as shown in Figure 96 12 Remove and discard the Second Brake B2 Piston Inner and Outer Seal and also the Second Brake B2 Piston Sleeve Outer Seal as shown in Figure 96 13 Remove the 13 M6 x 1 0 x 14 5 oil pump cover attaching bolts as shown in Figure 97 14 Remove the 1 M5 x 0 8 x 17 oil pump cover attaching bolt as shown in Figure 97 15 Carefully remove the Oil Pump Stator Shaft Assembly from the Oil Pump Body as shown in Figure 97 N S al O y NE Sa AS amp 207 OIL PUMP PLATE 208 OIL PUMP STATOR SHAFT ASSEMBLY 231 AUTOMATIC TRANSMISSION OIL PUMP COVER ATTACHING BOLTS M6 X 1 0 X 14 5 13 REQUIRED 232 AUTOMATIC TRANSMISSION OIL PUMP COVER ATTACHING BOLT M5 X 0 8 X 17 1REQUIRED Copyright O 2011 ATSG Figure 97 16 Remove the Oil Pump Plate Oil Pump O Ring Seal Discard the O Ring Seal and the Oil Pump Driven and Oil Pump Drive Gears from the Oil Pump Body as shown in Figure 98 17 Remove the Oil Pump Body Alignment dowels as shown in Figure 98 Cont d on page 48 202 OIL PUMP
102. TIGHTENING SPECIFICATIONS Ref Ot Fastener Fastener Specification No y Dimension N m in ft Ib Sagesse O M8x125x2600mm NMA Tensnisim Ce 09 9 MBxtasxissomm _ Nm Cover 7 Como Vale Body 49 Torgus Cone one 8 1 Tamon 0 CN ECT 2 1 2 Fastener Description 1 LE NON 2 NET N NE ON LE NN NON 2 NEE N NE ON DE EE YS TORK LR 09 9 MEET _ IS Copyright O 2011 ATSG Figure 275 160 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FASTENER TIGHTENING SPECIFICATIONS Ref Ot Fastener Fastener Specification No y Dimension N m in ft Ib Came ete larla E TE T Conta Valve Body 139 o ST No 2 Rear Control Valve Body 127 1 in Ib 1 ID Fastener Description ENN remonte Body i 009 1 7Nm th Vitte Comet Vive Body 0 IN e D NNNM Copyright O 2011 ATSG Figure 276 AUTOMATIC TRANSMISSION SERVICE GROUP 161 e ATSG Technical Service Information FASTENER TIGHTENING SPECIFICATIONS Ref Fastener Fastener Specification Fast D t ty decens Los No Dimension N m in ft Ib Reverse Shift Solenoid Valve S5 105 to Control Valve Body 139 102 M8 x 1 25 x 28 00 mm 25 N m 16 ft Ib Lock Up Control Solenoid Valve SLU 136 to Control Valve Body 139 107 M8 x 1 25 x 10 00 mm 25 N m 18 ft Ib Copyright O 2011 ATSG Figure 276 PRESSURE PORT LOCATIONS AND
103. TROL VALVE BODY ASSEMBLY MS X 0 8 X 50 MM 2 REQUIRED 121 MIDDLE CONTROL VALVE BODY ASSEMBLY Copyright 2011 ATSG Copyright 2011 ATSG Figure 157 Figure 158 AUTOMATIC TRANSMISSION SERVICE GROUP PGATSG FLIP VALVE BODY OVER 50 GASKETS AND PLATE ARE FACING UPWARD 123 REAR CONTROL VALVE BODY ASSEMBLY 124 REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY ASSEMBLY GASKET 125 REAR CONTROL VALVE BODY SPACER PLATE 126 REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKET 127 NO 2 REAR CONTROL VALVE BODY ASSEMBLY 128 CONTROL VALVE BODY BOLT M5 X 0 8 X 76 MM 1 REQUIRED 129 CONTROL VALVE BODY BOLT M5 X 0 8 X 49 5 MM 4 REQUIRED Copyright O 2011 ATSG Figure 159 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 11 Flip the control valve body assembly over so the No 2 rear control valve body is facing upward and remove the five control valve body bolts using an 8 mm socket as shown in Figure 159 12 Remove the No 2 rear control valve body the No 2 rear control valve body spacer plates and both gaskets as an assembly by holding the spacer plate against the No 2 rear control valve body and lift gently away from the rear control valve body as shown in Figure 159 13 To avoid losing small parts flip the No 2 rear control valve body assembly so the gaskets and spacer plate are facing upward a
104. TROL VALVE BODY ASSEMBLY LEGEND FRONT CONTROL VALVE BODY SOLENOID MODULATOR VALVE OIL FILTER PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SPRING ID NONE FORWARD CLUTCH C1 ACCUMULATOR BALL 12 EXHAUST CHECK VALVE 2 REQUIRED EXHAUST CHECK VALVE SPRING ID NONE 2 REQUIRED BORE PLUG RETAINER 4 3 2 X 5 X 10 mm BORE PLUG 4 SOLENOID MODULATOR VALVE SPRING ID YELLOW SOLENOID MODULATOR VALVE FORWARD CLUTCH C1 CONTROL VALVE NEUTRAL RELAY VALVE NEUTRAL RELAY VALVE SPRING ID LT GREEN 2ND COAST B1 CONTROL VALVE SPRING ID BLUE 2ND COAST B1 CONTROL VALVE MIDDLE CONTROL VALVE BODY SOLENOID OIL FILTER S2 S3 S4 SOLENOID OIL FILTER S1 S5 ACCUMULATOR CHECK VALVE BORE PLUG RETAINER 7 3 2 X 5 X 12 5 mm SOLENOID RELAY VALVE SLEEVE SOLENOID RELAY VALVE PLUNGER SOLENOID RELAY VALVE SOLENOID RELAY VALVE SPRING ID ORANGE REVERSE SHIFT CHECK BALL OUTER BUSHING REVERSE SHIFT CHECK BALL REVERSE SHIFT CHECK BALL INNER BUSHING PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE SPRING ID PURPLE PRESSURE REGULATOR VALVE PLUNGER PRESSURE REGULATOR VALVE SLEEVE U2 SHIFT VALVE U2 SHIFT VALVE SPRING ID LT GREEN BORE PLUG 3 M1 SHIFT VALVE M1 SHIFT VALVE SPRING ID LT GREEN M1 SHIFT VALVE BORE PLUG 1 U1 SHIFT VALVE U1 SHIFT VALVE SPRING ID LT GREEN BA RELEASE VALVE SPRING ID BLUE BA RELE
105. TSG Technical Service Information AW55 50 SN SERIES OPERATING MODES GM SATURN VEHICLE SHIFT MODES The control module provides earliest possible up shifts and lock up for best fuel economy Oil pressures are adjusted electronically for engagement and shift quality May also be referred to as Fail Safe or Limp Mode When fault codes are set this mode Protection will only allow limited ratio function Usually 5th gear in D or I ranges and 2nd gear in L Mode range If the key is cycled and the fault code is no longer current normal operation will be resumed If a code is current after ignition cycle then Protection Mode is maintained Hot Mode is initiated when the transaxle oil temperature exceeds 280 degrees F Shift Hot points are raised to a higher vehicle speed and the converter clutch will apply at a lower Mode vehicle speed to aid in cooling the unit Once the transaxle has cooled to less than 270 degrees F then Hot Mode will be turned off Cold Cold Mode is initiated when the engine coolant temperature is less than 120 degrees F Mode Shift points will be raised to a higher shift point to provide for a quicker engine warm up and to compensate for reduced engine power Uphill Ifthe engine torque is high and the vehicle speed is decreasing shift points will be raised Mode to compensate for the increase 1n load Towing or a heavily loaded vehicle can cause an Uphill Mode operating strategy to be in use as well Downhill
106. U Technical Service Information 4 5 Clutch C3 Assembly Cont d Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 10 Starting with a Steel Plate and alternating Steel Plates and Lined Plates install the 4 5 Clutch C3 steel and lined plates into the 4 5 Clutch C3 Drum as shown in Figure 140 11 Install the 4 5 Clutch C3 Backing Plate as shown in Figure 140 12 Install the 4 5 Clutch C3 Backing Plate Retaining Snap Ring as shown in Figure 140 13 Make sure the snap ring 1s fully seated in the snap ring groove 14 Check clutch clearance using an appropriate feeler gage as shown in Figure 141 If clutch clearance is not within specification select a different thickness backing plate from the chart in Figure 141 15 Set the 4 5 Clutch C3 Drum Assembly aside for final assembly Checking 9 5 Clutch C3 Clutch Clearance A A a ON Q Clutch Assembly Specifications 3 6 mm 0 142 in milan 584 4 5 CLUTCH C3 DRUM ASSEMBLY Copyright 2011 ATSG Figure 140 Figure 141 AUTOMATIC TRANSMISSION SERVICE GROUP 575 4 5 CLUTCH C3 BACKING PLATE RETAINING SNAP RING 576 4 5 CLUTCH C3 BACKING PLATE 577 4 5 CLUTCH C3 LINED PLATE 4 Required 578 4 5 CLUTCH C3 STEEL PLATE 4 Required e ATSG Technical Service Information LOW AND REVERSE BRAKE 83 FRONT INTERNAL GEAR AND LOW CLUTCH SPRAG F2 ASSEMBLY EXPLODED VIEW 514
107. UIRES 4 217 SECOND BRAKE B2 STEEL PLATE ASSEMBLY AF23 5 REQUIRES 3 AF33 5 REQUIRES 4 216 SECOND BRAKE B2 APPLY PLATE AF23 5 UNITS ONLY 215 SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY Copyright 2011 ATSG Copyright 2011 ATSG Figure 108 Figure 109 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 2 OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND SECOND BRAKE B2 ASSEMBLY 221 SECOND COAST BRAKE B1 PISTON INNER SEAL 222 SECOND COAST BRAKE B1 PISTON ASSEMBLY 223 SECOND COAST BRAKE B1 PISTON OUTER SEAL 224 SECOND COAST BRAKE B1 PISTON RETURN SPRING ASSEMBLY 225 SECOND COAST BRAKE B1 PISTON RETURN SPRING ASSEMBLY RETAINING SNAP RING Copyright O 2011 ATSG Figure 110 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information CARAS WR OR Nu 2 OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND SECOND BRAKE B2 ASSEMBLY 230 SECOND COAST BRAKE B1 BACKING PLATE RETAINING SNAP RING 229 SECOND COAST BRAKE B1 BACKING PLATE 228 SECOND COAST BRAKE B1 LINED PLATE ASSEMBLY 3 REQUIRED 227 SECOND COAST BRAKE B1 STEEL PLATE ASSEMBLY 3 REQUIRED Copyright O 2011 ATSG Figure 111 ATSG Oil Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 50 Install a new Inner O ring and Outer O ring Seal into the Second Coast Brake B1 Piston as shown in Figure 110 51 Coat the seals with a small amount of Trans Jel
108. VE VALVE BODY SEPARATOR PLATE AND GASKETS 45 COOLER BYPASS VALVE SPRING 123 REAR CONTROL VALVE BODY ASSEMBLY 46 TCC CHECK VALVE 130 CONTROL VALVE BODY BOLT 47 TCC CHECK VALVE SPRING M5 X 0 8 X 40 mm 1 Required 121 MIDDLE CONTROL VALVE BODY ASSEMBLY 132 CONTROL VALVE BODY BOLT 122 MIDDLE CONTROL VALVE BODY ASSEMBLY TO M5 X 0 8 X 35 mm 2 Required LOWER CONTROL VALVE BODY SEPARATOR PLATE 334 PRESSURE TAP DO NOT REMOVE AND GASKETS Copyright 2011 ATSG Copyright 2011 ATSG Figure 168 Figure 169 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS COMPONENT REBUILD Control Valve Body Assembly Cont d 41 Install the two accumulator check valves into the No 2 rear control valve body assembly then install the TCC check valve spring and the TCC check valve as shown in Figure 170 42 Install a new rear control valve body spacer plate to No 2 rear control valve body gasket onto the No 2 rear control valve body then install the rear control valve body spacer plate and the rear control valve body spacer plate to rear control valve body gasket as shown in Figure 170 43 If necessary use a small amount of Trans Jel to hold the gaskets and plate in place 20 ACCUMULATOR CHECK VALVE 81 TCC CHECK VALVE 82 TCC CHECK VALVE SPRING 124 REAR CONTROL VALVE BODY SPACER PLATE TO REAR CONTROL VALVE BODY GASKET 125 REAR CONTROL VALVE BODY SPACER PLATE 126 REAR CONTROL VALVE BODY SPACER PLATE TO NO 2 REAR CONTROL VALVE BODY GASKE
109. arious shift valves Reverse Ist Shift Solenoid SSI The reverse 1st shift solenoid is a normally open N O ON OFF type solenoid controlled by the TCM Line fluid feeds the S1 signal fluid circuit through orifice No 3 When the reverse Ist shift solenoid is energized ON SI fluid is blocked from exhausting through the solenoid creating S1 fluid pressure that acts on the Ul shift valve and the M1 shift valve When the reverse Ist shift solenoid is OFF any existing S1 signal fluid pressure is exhausted through holes at the base of the solenoid as shown in Figure 10 2 3 3 4 Shift Solenoid SS2 The 2 3 3 4 shift solenoid is a normally open N O ON OFF type solenoid controlled by the TCM Drive fluid feeds the S2 signal fluid through orifice No 25 When the 2 3 3 4 shift solenoid is energized ON S2 fluid is blocked from exhausting through the solenoid creating S2 signal fluid pressure that acts on the M2 shift valve against spring force to move the valve into the applied position When the 2 3 3 4 shift solenoid is OFF any existing S2 signal fluid pressure is exhausted through the end of the solenoid as shown in Figure 10 1 2 2 3 Reverse Shift Solenoid SS3 The 1 2 2 3 reverse shift solenoid is a normally closed N C ON OFF type solenoid controlled by the TCM Drive fluid feeds the S3 signal fluid through orifice No 24 When the 1 2 2 3 reverse shift solenoid is energized ON S3 signal flui
110. as indicated in Figure 132 18 Make sure the locating notch of the retaining snap ring is indexed into the proper location of the housing as shown in Figure 133 Cont d on page 67 Make sure the locating notch of the retaining snap ring is indexed in this position in the housing Copyright 2011 ATSG Figure 133 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Automatic Transmission Rear Cover 1 2 Reverse Brake B5 Housing Assembly Cont d 19 Install three new Forward C1 and Direct C2 Clutch Drum Fluid Sealing Rings as shown in Figure 134 20 Coat the three fluid sealing rings with a small amount of Trans Jel 21 Coat the Forward C1 and Direct C2 Clutch Drum Housing Thrust Bearing Race with a small amount of Trans Jel then place the thrust bearing race onto the 1 2 Reverse Brake B5 Housing as shown in Figure 134 22 Install two new O ring Seals onto the 4 5 Clutch C3 Apply Tube and coat the rings with a small amount of Trans Jel then install the tube by pressing downward gently or use a small plastic hammer and lightly tap the tube downward as shown in Figure 134 23 Install the 4 5 Clutch C3 Apply Tube Retaining Brackets and the four Retaining Bracket Attaching Bolts and hand tighten the bolts as shown in Figure 134 24 Install a new Sealing Ring onto the Forward Clutch C1 Accumulator Piston and a new O ring seal onto the Accumulator Housing as shown in Figure 134 25 Coat the Accumulator
111. asket differences Refer to Figure 271 for front control valve body casting differences refer to Figure 272 for middle control valve body casting differences AUTOMATIC TRANSMISSION SERVICE GROUP 139 ARTSU Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE EARLY VALVE BODY I D The SLT and the SLS solenoid connectors are facing upwards No letter version I or the letter A version 2 cast into the valve body next to the S 4 solenoid are considered early valve body assemblies The S I solenoid has the bolt on the left and connector to the right in early assemblies Ven Flat top S 2 solenoid indicates a NISSAN or VOLVO application Figure 259 140 AUTOMATIC TRANSMISSION SERVICE GROUP ARTSU Technical Service Information AWSS 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE LATE VALVE BODY I D The SLT and the SLS solenoid connectors are facing downwards Letter version 3 or the letter version 4 cast ia T into the valve body next to the SS S 4 solenoid are considered late valve body assemblies oor The S 1 solenoid has the connector to the left and bolt on the right in late assemblies Domed top S 2 solenoid indicates a GM SAAB SATURN application Figure 260 AUTOMATIC TRANSMISSION SERVICE GROUP ARTSU Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FO
112. cal Service Information Accelerator Pedal Position APP Sensor The APP sensor is monitored by the ECM to determine accelerator pedal position and is transmitted over the CAN bus to the TCM in order to help determine the appropriate line pressure shift pattern and TCC apply and release speeds In general with increased throttle position upshift speeds and line pressure both increase TCC Brake Switch This signal is transmitted over the CAN bus to the TCM and causes the TCM to command TCC release When the brake pedal is depressed at low speeds the TCM opens the ground path for the TCC electrical circuit which releases the converter clutch Controller Area Network CAN Bus The CAN bus consists of two twisted wires that connect the various vehicle control modules together allowing them to share information about vehicle conditions Note The sensor switch information listed above is not a complete listing of TCM inputs that may affect transaxle operation The combination and usage of these inputs may vary depending on model and the application Always refer to the appropriate service manual for specific electrical diagnosis information P0712 Transmission fluid temp sensor circuit low voltage short to ground 150 c 302 f P0713 P0717 P0722 Transmission fluid temp sensor circuit high voltage open circuit 40 c 40 f Input speed sensor loss of signal Output speed sensor loss of signal Continued on next Page Copyri
113. cond Brake B2 Assembly Cont d 31 Align the Fluid Pump Stator Shaft Assembly with the bolt holes shown through the Pump Plate and assemble the Fluid Pump Stator Shaft Assembly on to the Dowel Pins in the Pump Body as shown in Figure 104 32 Install and hand tighten 12 of the 13 Oil Pump Cover Attaching Bolts temporarily omitting the one indicated by the arrow as shown in Figure 104 NOTE The omitted bolt is left out in order to attach SST J 45166 Dial Indicator Tool for verifying piston travel Do not install Bolt here at this time NY SS al 10 0 R DAT SV x GE Ll LD 207 OIL PUMP PLATE 208 OIL PUMP STATOR SHAFT ASSEMBLY 231 AUTOMATIC TRANSMISSION OIL PUMP COVER ATTACHING BOLTS M6 X 1 0 X 14 5 13 REQUIRED 232 AUTOMATIC TRANSMISSION OIL PUMP COVER ATTACHING BOLT M5 X 0 8 X 17 1 REQUIRED Copyright 2011 ATSG Figure 104 Technical Service Information 33 Tighten the 12 installed Oil Pump Cover Attaching Bolts using the pattern as shown in Figure 105 34 Torque the bolts using an appropriate torque wrench referring to the Torque Specifications as indicated in Figure 105 Cont d on page 51 Do not install Bolt here at this time Do not install Bolt here at this time NY Tightening Torque Specifications Item to Apply Torque Specification Metric English Copyright 2011 ATSG Figure 105 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Pump Assemb
114. d is Pulse Width Modulated PWM and operates at a fixed frequency of 300 Hz cycles per second and from 0 0 to 1 1 amps As current flow is increased the pressure control to clutch apply is decreased As current flow is decreased the pressure control to clutch apply is increased as shown in Figure 13 If a total electronic failure is encountered this solenoid will put clutch apply pressure to maximum pressure and will set DTC P0970 or P0971 in the TCM memory Transmission Adapt Function Solenoid SL Programming within the TCM allows for automatic adjustments in pressure that are based on the changing characteristics of the internal transaxle components As the apply components within the transaxle wear the time to apply a clutch increases In order to compensate for this wear the TCM adjusts trim pressure by controlling the shift pressure control solenoid in order to maintain the originally calibrated shift timing This process is referred to as Adaptive Learning and is used to assure consistent shift feel and increase transaxle durability The TCM monitors the ISS and OSS during commanded shifts to determine if a shift is occuring too fast harsh or too slow soft and adjusts the shift pressure control solenoid signal to maintain a set shift feel TCC Lock Up Pressure Control Solenoid SLU The TCC lock up pressure control solenoid SLU is a normally closed 3 port solenoid and is a precision electronic pressure regulator tha
115. d is allowed to exhaust through the base of the solenoid as shown in Figure 10 When the 1 2 2 3 reverse shift solenoid is OFF S3 signal fluid is blocked from exhausting through the base of the solenoid creating S3 signal fluid pressure that acts on the U2 shift valve against spring force to move the valve into the applied position as shown in Figure 10 3 4 4 5 Shift Solenoid SS4 The 3 4 4 5 shift solenoid is a normally open N O ON OFF type solenoid controlled by the TCM Line fluid feeds the S4 signal fluid through orifice No 4 When the 3 4 4 5 shift solenoid is energized ON S4 fluid is blocked from exhausting through the solenoid creating S4 signal fluid pressure that acts on the U2 shift valve and the U1 shift valve When the 3 4 4 5 shift solenoid is OFF any existing S4 signal fluid pressure is exhausted through the end of the solenoid as shown in Figure 10 Reverse Ist Shift Solenoid SS7 Normally Open ELECTRICAL CONNECTOR 2 3 3 4 Shift Solenoid SS2 Normally Open ELECTRICAL CONNECTOR 7 2 2 3 Reverse Shift Solenoid 93 Normally Closed ELECTRICAL CONNECTOR 0 PE o PE U A AU O O 20909090 2808080808 50606050 050606 oog Ed m Se QN H e REECH Am ebe bebe CO OO Ol 20808080808080 sg SE O I ES O O O O 3 4 4 5 Shift Solenoid Normally Open ELECTRICAL CONNECTOR EXHAUST Copyright O 2011 ATSG Figure 10 AUTOMATIC TRANSM
116. ds a valve body from a Saturn vehicle with the dome top normally open solenoid may be used on a Nissan or Volvo vehicle providing the flat top normally closed solenoid is used in the solenoid S2 position and vice versa WHAT WILL NOT INTERCHANGE It is not recommended to interchange valve body sections because of worm track differences in the front control valve body and middle control valve body as well as differences in hole locations in the front control valve body separator plate and gaskets AUTOMATIC TRANSMISSION SERVICE GROUP ARTS Technical Service Information SERVICE INFORMATION CONT D VALVE BODY DIFFERENCES At first glance the four valve body versions appear to be very similar however there are some differences as previously mentioned that can cause consequence if castings plates or gaskets are interchanged Valve bodies with NO ID STAMP and ID STAMP C are almost identical in every way There are some differences in spring calibration however separator plates gaskets and castings are identical Valve bodies with ID STAMP A and ID STAMP B are almost identical in every way There are some differences in spring calibration however separator plate gaskets and castings are identical Refer to Figure 269 for front control valve body separator plate differences between castings NO ID STAMP ID STAMP C and ID STAMP B ID STAMP C Refer to Figure 270 for front control valve body to middle control valve body g
117. e 256 TORQUE PARK NEUTRAL POSITION SWITCH NUT TO 7 N m 62 in Ib TORQUE PARK NEUTRAL POSITION SWITCH STUD AND BOLT TO 25 Nom 18 Ib ft bn o fl Figure 257 Technical Service Information 116 Tighten the park neutral position switch nut to 7 N m 62 in lb as shown in Figure 256 117 Bend up the tabs of the locking washer to secure the nutas shown in Figure 256 118 Place the manual shift detent lever into the neutral position as shown in Figure 257 119 Install SST J 45404 onto the manual shift detent lever and rotate the park neutral position switch until the tool is aligned with the mark on the park neutral position switch as shown in Figure 257 120 Install a new o ring onto the fluid level indicator and coat with a small amount of Trans Jel and install the fluid level indicator into the transmission then the retaining bolt and hand tighten only as shown in Figure 258 121 Once the transmission has been reinstalled into the vehicle and the fluid level has been checked and verified as shown in Figure 4 torque the fluid level indicator retaining bolt to 0 N m 89 in Ib as shown in Figure 258 TORQUE THE FLUID LEVEL INDICATOR RETAINING BOLT TO 10 N m 89 in Ib ae Copyright O 2011 ATSG Figure 258 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG COMPLAINT CAUSE CORRECTION Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE Vehicles equipped
118. e condition can be corrected However the transmission will operate in reverse 1f selected as well as park and neutral TRANSAXLE CASE CONNECTOR AND INTERNAL WIRE HARNESS TRANSMISSION FLUID TEMPERATURE TFT SENSOR FI NG Copyright O 2011 ATSG Figure 5 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information ELECTRICAL COMPONENTS Cont d Transmission Fluid Temperature TFT Sensor The Transmission Fluid Temperature TFT sensor is part of the transaxle internal wire harness assembly as shown in Figure 5 The TFT sensor 1s a thermister and as such changes value based on temperature as shown in the chart in Figure 6 The TCM supplies a 5 volt reference signal to the TFT sensor and measures the voltage drop in the circuit When the transmission fluid is cold the TFT sensor resistance is high and the TCM detects high signal voltage As the fluid temperature warms to a normal operating temperature the resistance becomes less and the signal voltage decreases The TCM uses this information to maintain shift quality and TCC apply quality over the entire operating temperature range If the TCM detects an improper signal from the TFT sensor a DTC will be stored in TCM memory Transmission Fluid Temperature TFT Sensor Resistance Chart Figure 6 ARTS ELECTRICAL COMPONENTS Cont d Output Shaft Speed OSS Sensor The Output Shaft Speed OSS sensor is an active hall effect pickup located in th
119. e dial indicator base onto the pump body assembly where the attaching bolt was omitted as shown in Figure 113 66 Put the dial indicator on the Second Coast Brake B1 piston and set the dial indicator to a zero reading as shown in Figure 113 Caution When using compressed air wear safety glasses in order to help prevent injury to the eyes Checking Second Coast Brake B7 Clutch Clearance Set the Dial Indicator on the Second Coast Brake B1 Piston Carefully apply compressed air in this hole for Second Coast Brake B1 Clutch Assembly Specifications Second Coast Brake B1 Specification Metric English Second Coast Brake Bl Clearance 1 24 1 96 mm 0 049 0 077 in Copyright O 2011 ATSG Figure 113 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 67 Carefully pply a small amount of compressed air to the Second Coast Brake B1 passage as shown in Figure 113 and measure piston travel make certain the piston travels smoothly 68 Piston travel clutch clearance should be between 1 24 1 96 mm 0 049 0 077 in 69 There are no selective backing plates for the Second Coast Brake B1 If clutch clearance is not within specification make sure the clutch plates are assembled correctly 70 Remove SST J 45166 and J 45200 from the oil pump assembly 71 Install the omitted bolt as shown in Figure 114 72 Torque the remaining bolt to 12 N m 106 in Ib as shown in Figure 114
120. e top of the transaxle case as shown in Figure 7 This sensor is mounted in the case opposite the parking gear that is splined to the front differential transfer drive gear carrier assembly shaft The sensor is supplied with a reference voltage of 0 6 volts As the parking gear is rotated a square wave voltage signal 1s generated by the teeth on the parking gear as they pass by the sensor that is proportional to vehicle speed Refer to Figure 7 Output voltage from the sensor is fixed at 1 4 volts and does not depend on a rotational number for its input value Therefore the slower the parking gear rotates the fewer pulses will be detected by the TCM and conversely the faster the parking gear rotates a greater number of pulses will be detected by the TCM during the same time frame Ifthe TCM detects an improper signal from the OSS a DTC will be stored in the TCM memory Technical Service Information Input Shaft Speed ISS Sensor The Input Shaft Speed ISS sensor operates identically to the OSS sensor except that it uses the teeth on the forward direct clutch housing as the reluctor or rotor The forward direct clutch housing is driven at converter turbine speed The TCM uses transaxle input and output speeds to help determine line pressure transaxle shift patterns TCC apply pressure gear ratios and TCC slippage for diagnostic purposes Ifthe TCM detects an improper signal from the ISS a DTC will be stored in the TCM memory
121. eal when installing the detent lever 63 Install the transmission case fluid passage cover as shown in Figure 237 64 Install the two transmission case fluid passage cover retaining bolts M6 x 1 0 x 14 mm as shown in Figure 237 65 Torque the bolts to 5 Nm 44 in Ib as shown in Figure 237 66 Install two new O rings onto the third gear B4 apply pipe as shown in Figure 238 i E i M6 x 1 0x 14 mm 2 Required 5 Va TORQUE BOLTS TO J o EF 5 Nm diia in lb E mE E y Copyright O 2011 ATSG TETA 237 Technical Service Information 67 Coat the O rings with a small amount of Trans Jel and install the pipe into the transmission as shown in Figure 238 68 Install the apply pipe hold down bracket and the two hold down bracket retaining bolts M6 x 1 0 x 14 mm as shown in Figure 238 69 Torque the bolts to 5 Nm 44 in Ib as shown in Figure 238 70 Install a new fluid passage seal into the case as shown in Figure 239 Cont d on page 131 MG X 1 0 x 14 mm 2 Reguired TORQUE BOLTS TO 5 N m 44 in lb e A Copyright 2011 ATSG Figure 239 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG TRANSAXLE FINAL ASSEMBLY Cont d 71 Coat the front differential bearing assemblies with a small amount of atf and install the differential into the transmission as shown in Figure 240 72 Install the transmission fluid filter into the case as shown in Figure 241 73 Be careful to not dislodge the fluid filter seals 74
122. earance but has more metal added for extra strength and now measures approximately 0 065 in thickness Both the Ist and 2nd design brackets are used to retain the first version shorter design SLS and SLT solenoids to the body as shown in Figure 264 AUTOMATIC TRANSMISSION SERVICE GROUP 137 PAATSG Technical Service Information AWSS 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE CORRECTION continued The first version SLS and SLT solenoids have their electrical connectors turned up with the SLS connector being green and the SLT connector being blue The first version SLS and SLT solenoids can be identified by the round hole in the valve portion ofthe solenoid that is nextto the can portion that contains the winding The second design SLS and SLT solenoids are longer than the first design and still have the electrical connectors facing upwards The second design solenoids require the 3rd design retaining bracket which can be identified by a protrusion at the bottom left that looks a bit like a backwards L as indicated in Figure 264 The third design SLS and SLT solenoids are the same length as the second design solenoids and use the same 3rd design retaining bracket but the electrical connectors are now facing downward The third design SLS and SLT solenoids are used in the B and C 3rd and 4th generation valve bodies only as shown in Figure 265 Using an incorrect retaining bracket or rotating the Ist or 2nd design retaining b
123. early short SLS SLT solenoids These solenoids use the early Ist or 2nd design bracket only Either one these solenoids can be used in an early valve body showing no letter or the letter A cast next to the S 4 solenoid Both of these solenoids have their electrical connector facing up E These solenoids use the later 3rd design bracket only This solenoid has the electrical connector facing downward and is only used in valve bodies with either letter B or in the casting next to the S 4 solenoid E This solenoid uses the later 3rd design bracket only Figure 265 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE EARLY SLS SLT SOLENOID RETAINING BRACKET ORIENTATION CORRECT INSTALLATION will have the narrow end up and the SLS and SLT solenoid passages will be aligned with the valve body casting INCORRECT INSTALLATION will have the narrow end down and the SLS and SLT solenoid passages will not be aligned with the valve body casting esse ur dd Veto Figure 266 146 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES VALVE BODY and SOLENOID I D FOR SERVICE EARLY SLS SLT SOLENOID RETAINING BRACKET ORIENTATION CORRECT INSTALLATION L SLS and SLT solenoid passages will be aligned with the valve body casting SLS and SLT
124. echnical Service Information AUTOMATIC TRANSMISSION REAR COVER AND 7 2 REVERSE BRAKE B5 HOUSING ASSEMBLY LEGEND 66a A T FLUID PRESSURE TEST PORT DIRECT CLUTCH C2 PRESSURE 612 FORWARD CLUTCH C1 ACCUMULATOR PISTON 66b A T FLUID PRESSURE TEST PORT LUBRICATION PRESSURE 613 FORWARD CLUTCH C1 ACCUMULATOR PISTON FLUID SEALING RING 66c A T FLUID PRESSURE TEST PORT FORWARD CLUTCH C1 PRESSURE 614 FORWARD CLUTCH C1 ACCUMULATOR PISTON CUSHION 66d A T FLUID PRESSURE TEST PORT 1 2 REVERSE BRAKE B5 PRESSURE SPRING ID COLOR NATURAL 66e A T FLUID PRESSURE TEST PORT FORWARD CLUTCH C1 PRESSURE 615 FORWARD CLUTCH C1 ACCUMULATOR COVER O RING SEAL 66f A T FLUID PRESSURE TEST PORT LUBRICATION PRESSURE 616 FORWARD CLUTCH C1 ACCUMULATOR HOUSING 66g A T FLUID PRESSURE TEST PORT LUBRICATION PRESSURE 617 FORWARD CLUTCH C1 ACCUMULATOR HOUSING ATTACHING BOLT M5 X 0 8 X 12MM 2 REQUIRED 67 AIT FLUID PRESSURE TEST PORT PLUG O RING SEAL 7 REQUIRED 618 1 2 REVERSE BRAKE B5 CUSHION APPLY PLATE 1 REQUIRED 600 1 2 REVERSE BRAKE B5 PISTON RETURN SPRING RETAINING SNAP RING 619 1 2 REVERSE BRAKE B5 STEEL PLATE 6 REQUIRED 601 1 2 REVERSE BRAKE B5 PISTON RETURN SPRING ASSEMBLY 620 1 2 REVERSE BRAKE B5 LINED PLATE 6 REQUIRED 602 1 2 REVERSE BRAKE B5 PISTON INNER O RING SEAL 621 1 2 REVERSE BRAKE B5 BACKING PLATE SELECTIVE 603 1 2 REVERSE BRAKE B5 PISTON ASSEMBLY 622 1 2 REVERSE BRAKE B5 BACKING PLATE RETAINING
125. enoid B Solenoid S2 Circuit Failure Shift Solenoid C Solenoid S3 Circuit Failure Shift Solenoid C Stuck On Solenoid S3 Performance Shift Solenoid D Solenoid S4 Circuit Failure Shift Solenoid E Solenoid S5 Circuit Failure Pressure Control Solenoid B Shift Pressure Solenoid SLS Circuit Failure Poor Shift Quality Pressure Control Solenoid C Shift Pressure Solenoid SLU Circuit Failure Pressure Control Solenoid C Shift Pressure Solenoid SLU Stuck On Manual Mode Switch Circuit Manual Mode Switch Shorted or Open TCM Power Input Signal Electronic Throttle Control System CAN Communication Circuit CAN Communication Line Shorted or Open Copyright 2011 ATSG Figure 282 I AUTOMATIC TRANSMISSION SERVICE GROUP 16 PGATSG Technical Service Information SPECIAL SERVICE TOOLS SST SECTION J 45161 Manual Shift Shaft Bearing Replacer J 45164 Spring Compressor J 45166 Dial Indicator Extension Rod 8 inch J 45184 Differential Bearing Race Installer J 45185 Bore Gage Set Figure 283 AUTOMATIC TRANSMISSION SERVICE GROUP J 45187 Differential Output Shaft Oil Seal Installer J 45186 Forward and Direct Clutch Spring Compressor J 45200 Dial Indicator Set J 45201 Cooler Line Seal Remover J 45404 Transmission Indicator Alignment Tool Copyright 2011 ATSG PGATSG Technical Service Information SPECIAL SERVICE TOOLS SST SECTION J 4500 Seal Remover J 4505
126. erations License Agreement Number 0510718 No part of any ATSG publication may be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying recording or otherwise without written permission of Automatic Transmission Service Group This includes all text illustrations tables and charts The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability but ATSG does not guarantee its accuracy Copyright ATSG 2011 PETER LUBAN WAYNE COLONNA DALE ENGLAND TECHNICAL CONSULTANT TECHNICAL CONSULTANT TECHNICAL CONSULTANT GERALD CAMPBELL JIM DIAL TECHNICAL CONSULTANT TECHNICAL CONSULTANT JERRY GOTT ED KRUSE TECHNICAL CONSULTANT TECHNICAL CONSULTANT CLAY WICKHAM GREGORY LIPNICK TECHNICAL CONSULTANT TECHNICAL CONSULTANT JON GLATSTEIN DAVID CHALKER TECHNICAL CONSULTANT TECHNICAL CONSULTANT JOS GARCIA GREG CATANZARO TECHNICAL CONSULTANT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 18635 SW107th AVENUE MIAMI FLORIDA 33157 305 670 4161 CLA ER at EK EK EK al al TATA T EA TEA TATA TATA AT36 SATURN GM S AA B CASE PASSAGE ID AND AIR PRESSURE TEST PORTS EE 163 AUTOMATIC TRANSMISSION SERVICE GROUP 18635 SW 107th AVENUE MIAMI FLORIDA 33157 305 670 4161 Y NISSAN VOLVO Y Y AF23 33 5 AW55 50 51SN Y RESF22A Y INDEX Y Y CUT AWAY VIEW AND
127. g Assembly then using a pair of snap ring pliers remove the Second Coast Brake B1 Piston Return Spring Retaining Snap Ring as shown in Figure 93 4 Remove the Second Coast Brake Bl Piston Return Spring Assembly from the oil pump assembly as shown in Figure 93 Cont d on page 45 e ATSG Technical Service Information Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d Caution When using compressed air wear 10 Using a pair of snap ring pliers remove the safety glasses in order to help prevent injury to Second Brake B2 Piston Return Spring the eyes Assembly Retaining Snap Ring as shown in 5 While pulling upward on the piston assembly Figure 96 carefully apply compressed air into the passage for the Second Coast Brake B1 in the pump Cont d on page 47 assembly and remove the Second Coast Brake B1 Piston Assembly as shown in Figure 94 6 Remove and discard the Second Coast Brake B1 Piston Inner Seal and Outer Seal as shown in Figure 94 7 Using SST J 28585 or a small screw driver remove Second Brake B2 Backing Plate Retaining Snap Ring as shown in Figure 95 8 Remove the Second Brake B2 Backing Plate the Lined Plate and Steel Plate Assemblies discard the lined plates and the Apply Plate as shown in Figure 95 9 Remove the Second Brake B2 Piston Return Spring Assembly as shown in Figure 95 Carefully apply compressed air in th
128. ge cover retaining bolts as shown in Figure 38 47 Remove the transmission case fluid passage cover as shown in Figure 38 Cont d on page 24 8 ATSG TRANSAXLE DISASSEMBLY CONT D 48 Lift the manual valve detent spring upward away from the manual valve detent lever and slide the detent lever in the direction of the arrow as shown in Figure 39 49 Rotate the manual valve detent lever forward in order to disengage the parking pawl actuator rod and remove the actuator rod from the manual valve detent lever then remove the actuator rod from the transmission as shown in Figure 39 50 Remove the manual valve detent lever assembly from the case in the direction of the arrow as shown in Figure 39 51 Remove the two manual valve detent lever spring retaining bolts as shown in Figure 40 52 Remove the manual valve detent lever spring by lifting and sliding in direction of the arrow as shown in Figure 40 Figure 40 Technical Service Information 53 Remove the parking pawl retaining sha t by lifting straight up as shown in Figure 41 54 Remove the parking pawl retaining shaft return spring as shown in Figure 41 55 Remove the parking pawl actuating bracket and the parking pawl lever as shown in Figure 42 Cont d on page 25 N Copyright 2011 ATSG Figure 42 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG TRANSAXLE DISASSEMBLY CONT D 56 Remove the parking pawl pin spring retaining bolt as shown in Figure
129. ght O 2011 ATSG Figure 18 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information SATURN VUE AF2333 5 DIAGNOSTIC TROUBLE CODES CODE P0727 P0730 P0731 P0732 P0733 P0734 P0735 P0736 P0741 P0742 P0744 P0762 P0962 P0963 P0966 P0967 P0970 P0971 P0973 P0974 P0976 P0977 P0979 P0980 P0982 P0985 P0985 P0986 P1719 P1779 P1780 P1781 P1791 P1792 P1868 DESCRIPTION Engine RPM sensor fault via ECM thru CAN Incorrect Ist gear Low ratio No Engine Braking on Decel in Low Range Incorrect Ist gear ratio Incorrect 2nd gear ratio Incorrect 3rd gear ratio Incorrect 4th gear ratio Incorrect 5th gear ratio Incorrect Reverse ratio TCC excessive slip or stuck off TCC low slip or stuck on TCC intermittent system fault Mechanical SS3 stuck open Mechanical Line Pressure Control Solenoid Low current Line Pressure Control Solenoid High current TCC Pressure Control Solenoid Low current TCC Pressure Control Solenoid High current Shift Pressure Control Solenoid Low current Shift Pressure Control Solenoid High current SSI Control Circuit Low voltage SSI Control Circuit High voltage SS2 Control Circuit Low voltage SS2 Control Circuit High voltage SS3 Control Circuit Low voltage SS3 Control Circuit High voltage SS4 Control Circuit Low voltage SS4 Control Circuit High voltage SS5 Control Circuit Low voltage SS5 Control Circuit High voltage Incorrect shifting detected Mechanical
130. gure 32 33 Set the pump assembly aside for cleaning and component rebuild 34 Using a soft faced hammer or plastic mallet gently tap and loosen the converter housing as shown in Figure 33 35 Remove the converter housing from the transmission case by lifting straight up 36 Set the converter housing aside for cleaning and component rebuild Cont d on page 23 Tap here gently to loosen converter housing DN a E 1 b a d EN il E 3 Figure 33 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS TRANSAXLE DISASSEMBLY CONT D 37 Remove the ATF fluid filter retaining bolt as shown in Figure 34 38 Remove and discard the ATF fluid filter by lifting straight up as shown in Figure 34 39 Remove the front differential carrier assembly by lifting straight up as shown in Figure 35 40 Set differential carrier assembly aside for cleaning and component rebuild 41 Remove the 2nd coast clutch hub outer race and the 2nd coast clutch hub as shown in Figure 36 42 Set the 2nd coast clutch outer race and hub assembly aside for cleaning and component rebuild 43 Remove the three transmission fluid baffle retaining bolts as shown in Figure 37 44 Remove the transmission fluid baffle as shown in Figure 37 45 Remove the transmission case fluid passage seal as shown in Figure 37 Figure 35 I AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 46 Remove the two transmission case fluid passa
131. ired 811 AUTOMATIC TRANSMISSION CASE PLUG O RING 800 TORQUE CONVERTER HOUSING AXLE SEAL 812 AUTOMATIC TRANSMISSION VENT PIPE 801 TORQUE CONVERTER HOUSING ASSEMBLY 813 AUTOMATIC TRANSMISSION VENT HOSE CLIP 802 N i Ar TRANSFER DRIVE GEAR FRONT LUBE 814 AUTOMATIC TRANSMISSION VENT HOSE 803 AUTOMATIC TRANSMISSION FLUID BAFFLE 815 AUTOMATIC TRANSMISSION VENT ASSEMBLY 804 TRANSMISSION LUBE FLUID TUBE 816 DIFFERENTIAL TRANSFER DRIVE GEAR FRONT BEARING ASSEMBLY 805 LUBE FLUID TUBE HOLD DOWN BRACKET 806 LUBE FLUID TUBE HOLD DOWN BRACKET RETAINING BOLT 817 FRONT DIFFERENTIAL ASSEMBLY BEARING RACE M6 x 1 0 x 14 1 Required 819 AUTOMATIC TRANSMISSION FLUID DRAIN PLUG 807 TRANSMISSION FLUID BAFFLE RETAINING BOLT M6 x 1 0 x 14 3 Required 820 AUTOMATIC TRANSMISSION FLUID DRAIN PLUG WASHER 808 TRANSMISSION METAL PARTICLE COLLECTOR MAGNET 3 Required 821 AUTOMATIC TRANSMISSION CASE PLUG O RING Copyright 2011 ATSG Figure 62 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Torque Converter Housing 1 Disassemble the Torque Converter Housing using the diagram in Figure 62 as a guide 2 Using SST J45000 or other equivalent seal removal tool remove the torque converter housing axle seal from the torque converter housing as shown in Figure 63 3 Remove the transmission fluid lube tube bracket retaining bolt and remove the bracket as shown in Figure 6
132. is hole for Second Coast Brake B1 2 OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND 2 OIL PUMP ASSEMBLY SECOND COAST BRAKE B1 AND SECOND BRAKE B2 ASSEMBLY SECOND BRAKE B2 ASSEMBLY 224 SECOND COAST BRAKE B1 PISTON RETURN SPRING 221 SECOND COAST BRAKE B1 PISTON INNER SEAL ASSEMBLY 222 SECOND COAST BRAKE B1 PISTON ASSEMBLY 225 SECOND COAST BRAKE B1 PISTON RETURN SPRING 223 SECOND COAST BRAKE B1 PISTON OUTER SEAL ASSEMBLY RETAINING SNAP RING Copyright 2011 ATSG Copyright 2011 ATSG Figure 93 Figure 94 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information Carefully apply compressed air in this hole for Second Coast Brake B1 SECOND BRAKE B2 BACKING PLATE RETAINING SNAP RING SECOND BRAKE B2 BACKING PLATE SELECTIVE 214 SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY SECOND BRAKE B2 LINED PLATE ASSEMBLY RETAINING SNAP RING AF23 5 REQUIRES 2 AF33 5 REQUIRES 4 213 SECOND BRAKE B2 PISTON SLEEVE INNER SEAL SECOND BRAKE B2 STEEL PLATE ASSEMBLY 212 SECOND BRAKE B2 PISTON SLEEVE AF23 5 REQUIRES 3 AF33 5 REQUIRES 4 211 SECOND BRAKE B2 PISTON SLEEVE OUTER SEAL SECOND BRAKE B2 APPLY PLATE AF23 5 UNITS ONLY 210 SECOND BRAKE B2 PISTON ASSEMBLY SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY 209 SECOND BRAKE B2 PISTON ASSEMBLY OUTER SEAL Copyright 2011 ATSG Copyright 2011 ATSG Figure 95 Figure 96 AUTOMA
133. islodged as shown in Figure 216 19 Install the forward C1 and direct C2 clutch housing assembly into the transaxle with a twisting motion so that the forward and direct clutches are splined onto the rear sun gear and rear internal gear as shown in Figure 217 20 Install five new case passage oil seals and hold them in place with a small amount of Trans Jel as shown in Figure 217 21 Install the case cover assembly onto the transmission and install the 12 bolts hand tight only as shown in Figure 218 22 Rotate the transmission so the front section of the case 1s facing upward as shown in Figure 219 23 Place SST J 45200 or similar dial indicator base onto the transfer gear as shown in Figure 219 Zz Er 7 Copyright 2011 ATSG Figure 216 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 24 Place the dial indicator on the turbine shaft and set the dial indicator to zero 25 Lift the turbine shaft gently until it stops and record the reading on the dial indicator 26 The dial indicator reading is the end play END PLAY MEASUREMENT SHOULD BE 0 188 0 570mm 0 007 0 022 in Cont d on page 126 Dial Indicator Goes Here Set to Zero Reading di Dial Indicator Base Goes Here mer Copyright 2011 ATSG ETA Figure 219 e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 36 Install the 1 2 Reverse planetary carrier into the 27 f e
134. l need to be repaired or replaced Failure to do so will result in premature transmission failure 8 Using SST J 44809 or other adequate seal installer and a hammer install a new automatic transmission axle seal as shown in Figure 78 9 Using SST J 45161 or other adequate driver and a hammer install a new shift shaft bearing assembly then install a new shift shaft seal as shown in Figure 79 10 Using SST J 41239 1A or other adequate seal installer and a hammer install two new transmission fluid cooler line seals as shown in Figure 79 Cont d on page 37 Inspect the transmission case assembly for wear in the area shown below This is an extremely critical area that needs to be addressed 87 AUTOMATIC TRANSMISSION FLUID COOLER LINE SEALS 2 Required 713 MANUAL SHIFT SHAFT SEAL 714 MANUAL SHIFT SHAFT BEARING ASSEMBLY Copyright 2011 ATSG Copyright 2011 ATSG Figure 77 Figure 79 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Technical Service Information COMPONENT REBUILD CONT D Transmission Case Assembly Checking Differential Assembly Rotational Torque 1 Rotate the transmission case assembly so the converter housing side is facing upward and install the front differential assembly into the empty case as shown in Figure 80 2 Install the converter housing onto the transmission case assembly and install the twelve converter housing attaching bolts hand tightening only as shown in Figure 81 3 Using an
135. ld the bearing in place with a small amount of Trans Jel as shown in Figure 212 Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation Make sure snap ring is fully seated in the snap ring groove EET Copyright 2011 ATSG Figure 211 Copyright 2011 ATSG Figure 212 Technical Service Information 12 Install the L R brake B3 backing plate into the case 13 Starting with a lined plate and alternating lined and steel plates install the friction plates into the case 14 Install the remaining backing plate into the case and the backing plate retaining snap ring 15 Make sure the snap ring 1s fully seated in the snap ring groove in the case as shown in Figure 213 16 Install the front planet carrier and sun gear assembly into the transaxle with a twisting motion as shown in Figure 214 Cont d on page 125 Make sure snap ring is fully seated in the snap ring groove Copyright 2011 ATSG r x Copyright O 2011 ATSG Figure 214 124 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG TRANSAXLE FINAL ASSEMBLY Cont d 17 Install the rear internal gear assembly into the transaxle with a twisting motion and make sure the rear sun gear thrust bearing race does not become dislodged as shown in Figure 215 18 Install the rear sun gear assembly with a twisting motion and make sure the input shaft thrust bearing assembly does not become d
136. lowing conditions must be met for this mode to function 1 The gear shifter must be in the D 4 or 3 position 2 The transaxle must be operating 1n 3rd 4th or 5th gear 3 The transmission input speed must be 1100 RPM or greater and the throttle opening must be 35 or less 4 Engine coolant must reach a minimum temperature requirement 5 Transmission oil temperature must be at least 104 degrees F but is not to exceed 248 degrees F NOTE The friction properties of this transmission fluid Type T IV are different from other fluids and will affect converter clutch operation and shift quality The manufacturer states that failure to use the correct fluid can cause damage and fault codes to be stored AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information AW55 50 SN SERIES OPERATING MODES NISSAN VEHICLE SHIFT MODES Upslope When the TCM detects an upslope because of an increase in engine load and decrease of Mode acceleration this mode will raise shift points to prevent busy shifting of transaxle Downslope When the TCM detects a downslope because of an increase in acceleration with the Mode throttle fully closed this mode provides moderate engine braking by raising shift points Hot Mode This mode lowers the ATF temperature by altering shift points when the temperature 1s Control extremely high Down Shift In order to prevent an engine over speed condition down shifts are allowed only under a
137. lows for automatic adjustments in pressure that are based on the changing characteristics of the internal transaxle components As the apply components within the transaxle wear the time to apply aclutch increases In order to compensate for this wear the TCM adjusts trim pressure by controlling the line pressure control solenoid in order to maintain the originally calibrated shift timing This process is referred to as Adaptive Learning and is used to assure consistent shift feel and increase transaxle durability The TCM monitors the ISS and OSS during commanded shifts to determine if a shift is occuring too fast harsh or too slow soft and adjusts the line pressure control solenoid signal to maintain a set shift feel Technical Service Information Reverse Shift Solenoid SS5 Normally Closed ELECTRICAL CONNECTOR PLUNGER Copyright 2011 ATSG line Pressure Control Solenoid SLT Normally Open SPOOL SPOOL PLUNGER VALUE VANE SPRING PRESSURE PRESSURE SUPPLY CONTROL SOLENOID THROTTLE MODULATOR SIGNAL ELECTRICAL CONNECTOR Copyright 2011 ATSG Figure 12 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS ELECTRICAL COMPONENTS Cont d Shift Pressure Control Solenoid SLS The shift pressure control solenoid 15 a normally open 3 port solenoid and is a precision electronic pressure regulator that controls transaxle clutch apply pressure based on current flow through its coil windings This solenoi
138. lt it in place then put the dial indicator on the direct clutch piston and set the dial indicator to a zero reading as shown in Figure 126 24 Using a small amount of compressed air carefully apply pressure to the ports for the Forward C1 and Direct C2 clutch as shown in Figure 126 25 Use the chart in Figure 126 to determine clutch clearance 26 If clutch clearance is not within specification select a different thickness backing plate from the chart shown in Figure 126 27 Set the completed drum assembly aside for final assembly Checking Forward C7 and Direct C2 Clutch Clearance Carefully apply air Carefully apply air here for C1 0 74 1 06 mm 0 029 0 042 in Specification Metric English 0 76 1 24 mm 0 030 0 049 in Available Forward C1 and SEH Direct C2 Backing Plate Thicknesses 567 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY 568 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY THRUST BEARING RACE SELECTIVE 569 FORWARD C1 AND DIRECT C2 CLUTCH DRUM HOUSING ASSEMBLY THRUST BEARING ASSEMBLY 570 TURBINE SHAFT SEAL RING 4 0 mm 0 157 in Copyright 2011 ATSG Copyright 2011 ATSG Figure 125 Figure 126 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Technical Service Information AUTOMATIC TRANSMISSION REAR COVER AND 7 2 REVERSE BRAKE B5 HOUSING ASSEMBLY Copyright 2011 ATSG Figure 127 AUTOMATIC TRANSMISSION SERVICE GROUP ARTSU T
139. ly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 35 Once the Oil Pump Cover Attaching Bolts are tightened to the proper torque specification inspect the pump gears for smooth rotation 36 Install the pump assembly on the torque converter as shown in Figure 106 37 Rotate the pump assembly to insure smooth rotation of the pump gears as shown in Figure 106 38 Be careful not to damage the pump seal during this operation 39 Install a new Second Brake B2 Piston Outer Seal and Inner Seal onto the Second Brake B2 Piston and anew Second Brake B2 Piston Sleeve Outer Seal as shown in Figure 107 40 Coat the seals with a small amount of Trans Jel 41 Install the Second Brake B2 Piston Sleeve into the pump assembly using a twisting motion 42 Install the Second Brake B2 Piston inside of the Piston Sleeve using a twisting motion 43 Install the Second Brake B2 Piston Return Spring Retaining Snap ring onto the pump assembly as shown in Figure 107 making certain the retaining snap ring is fully seated Technical Service Information Cont d on page 52 Make certain Pump Gears Rotate Freely Both Directions 214 SECOND BRAKE B2 PISTON RETURN SPRING ASSEMBLY RETAINING SNAP RING 213 SECOND BRAKE B2 PISTON SLEEVE INNER SEAL 212 SECOND BRAKE B2 PISTON SLEEVE 211 SECOND BRAKE B2 PISTON SLEEVE OUTER SEAL 210 SECOND BRAKE B2 PISTON ASSEMBLY 209 SECOND BRAKE
140. ly provides additional torque multiplication when required The pressure plate when applied provides a mechanical direct drive coupling of the engine to the turbine shaft of the transmission The three planetary gear sets provide five gear ratios forward and one gear ratio in reverse Gear ratio change 1s provided automatically through the use of the Transmission Control Module TCM The TCM receives and monitors input from various electronic sensors then utilizes the information to change the gear ratios as needed for optimum efficiency The TCM activates five on off shift control solenoids and three duty cycle solenoids within the transmission to control functions such as desired gear ratio shift timing and pressure control The TCM also controls the apply and release of the torque converter clutch which allows the engine to deliver maximum fuel efficiency without sacrificing vehicle performance The hydraulic system consists of a gear type pump four control valve bodies case cover converter housing and transmission case The pump functions to maintain adequate working pressure to stroke the servo and clutch pistons that apply or release the friction components These friction components when applied or released support the fully automatic shifting qualities of the transmission The friction components used in this transmission consist of seven multiple disc clutches and one brake band The multiple disc clutches combi
141. ly where the attaching bolt was omitted as shown in Figure 112 61 Put the dial indicator on the Second Brake B2 Piston Return Spring and set the dial indicator to a zero reading as shown in Figure 112 Caution When using compressed air wear safety glasses in order to help prevent injury to the eyes Technical Service Information 62 Carefully apply a small amount of compressed air to the Second Brake B2 passage as shown in Figure 112 and measure piston travel make certain the piston travels smoothly 63 Piston travel clutch clearance should be between 1 10 1 50 mm 0 043 0 059 in 64 If clutch clearance is not within specification select another backing plate using the chart in Figure 112 as areference Cont d on page 55 Checking Second Brake 82 Clutch Clearance Set the Dial Indicator on the Second Brake B2 Piston Return Spring Carefully apply compressed air in this hole for Second Brake B2 Clutch Assembly Specifications Second Brake B2 Specification Metric English 3 6 mm 0 142 in 3 8 mm 0 150 in 4 0 mm 0 157 in Copyright 2011 ATSG Figure 112 Second Brake B2 Clearance 1 10 1 50 mm 0 043 0 059 in Available Second Brake B2 Backing Plate Thicknesses AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Oil Pump Assembly Second Coast Brake B1 and Second Brake B2 Assembly Cont d 65 Using SST J 45166 and J 45200 or other adequate dial indicator set th
142. mation module will change the symbol on the instrument cluster from D to the gear that has been selected signal is sent to the gear selector to illuminate the M and turn off the other LEDs on the shifter console The TCM will over ride the driver s selection under certain operating conditions The following factors apply during Geartronic shifting 1 Only Ist 2nd or 3rd gears can be selected from a stop The transmission will not up shift to 4th gear until a minimum speed of at least 19 MPH has been attained The transmission will not up shift to 5th gear until a minimum speed of 25 MPH has been attained 2 Automatic downshifts will occur below certain speeds if the driver forgets to manually down shift the transaxle Manual up shifting 1s still necessary after automatic down shifting has occurred 3 Kick down is not available when using Geartronic shifting mode 4 The TCM will not allow the transaxle to be manually down shifted if the engine speed would exceed 6000 RPM 5 If the transmission oil temperature gets too high the TCM will select an appropriate gear so that lock up function can be utilized 6 Torque converter clutch lock up is only possible in 3rd 4th and 5th gears VOLVO SLIPPING LOCK UP Slipping lock up allows for a smoother converter clutch engagement while reducing torsional vibrations and noise The control module maintains a 50 200 RPM torque converter clutch slip while operating in this mode The fol
143. mbly front differential bearing race from the 6 Make a notation of the rotational torque reading transmission case as shown in Figure 84 Rotational Torque Specification 11 Remove the front differential bearing race Rotational torque should be between 0 70 1 20 selective shim as shown in Figure 84 Nm 6 11 Ib in 7 1f rotational torque is within specification front Cont d on page 39 differential bearing race selective shim replacement will not be necessary 8 If rotational torque is not within specification it will be necessary to replace the front differential bearing race selective shim Rotational Torque Specification 0 70 7 20 Nm 6 77 lb in SST DT 47687 Rotational Torque Adapter NL 29222 AE 17 TRANSMISSION CASE ASSEMBLY 88 FRONT DIFFERENTIAL BEARING RACE SELECTIVE SHIM 90 FRONT DIFFERENTIAL BEARING RACE Copyright 2011 ATSG Copyright 2011 ATSG Figure 83 Figure 84 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS Technical Service Information COMPONENT REBUILD CONT D Rotational Torque Measurement Cont d Front Differential Bearing Race 12 If front differential bearing race selective shim Selective Shim replacement is needed select an appropriate shim using the chart in Figure 85 as a guide 13 If rotational torque measurement is less than specification a thicker shim will be required 14 If rotational torque measurement is greater than specification a thinner shim will be
144. n 29 Install two new rear control valve body cover plate gaskets then install the cover plates and thread the bolts into the rear control valve body 30 Tighten the rear control valve body cover plate attaching bolts using a speed handle 31 Torque the rear control valve body cover plate attaching bolts to 7 Nm 62 in b Cont d on page 88 NO 2 REAR CONTROL VALVE BODY EXPLODED VIEW 20 ACCUMULATOR CHECK VALVE 76 NO 2 REAR CONTROL VALVE BODY 77 BORE PLUG RETAINER 2 3 2 X 5 X 15 mm 78 2ND CLUTCH B2 CONTROL VALVE PLUG 79 2ND CLUTCH B2 CONTROL VALVE SPRING 80 2ND CLUTCH B2 CONTROL VALVE 81 TCC CHECK VALVE 82 TCC CHECK VALVE SPRING REVERSE INHIBIT CHECK BALL INNER BUSHING REVERSE INHIBIT CHECK BALL REVERSE INHIBIT CHECK BALL OUTER BUSHING LOCK UP CONTROL VALVE LOCK UP CONTROL VALVE PLUNGER LOCK UP CONTROL VALVE SPRING LOCK UP CONTROL VALVE SLEEVE BORE PLUG RETAINER 1 3 2 X 5 X 21 2 mm Copyright 2011 ATSG Figure 164 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 48 49 50 9T 92 53 54 55 56 58 99 60 61 Technical Service Information REAR CONTROL VALVE BODY DOVERBDATE EXPLODED VIEW n UE 7 N m 62 in Ib COVER PLATE ATTACHING BOLT TORQUE 7 N m 62 in Ib REAR CONTROL VALVE BODY LOCK UP RELAY CONTROL VALVE SLEEVE LOCK UP RELAY CONTROL VALVE PLUNGER LOCK UP RELAY CONTROL VALVE SPRING LOCK UP RELAY CONTROL VALVE 1 2 REVERSE
145. n appropriate torque wrench torque the 4 5 Clutch Apply Tube Retaining Brackets Bolts to 7 N m 62 in lb as shown in Figure 136 35 Torque the Forward Clutch Accumulator Housing Attaching Bolts to 10 N m 89 nn Ib as shown in Figure 136 36 Set the completed housing aside for final assembly Tightening Torque Specifications Item to Apply Torque Specification Metric English 611 4 5 Clutch Apply Tube Retaining Bracket Bolts 7 N m 62 in lb 5 x 0 8 x 12 mm 4 Required 617 Forward Clutch Accumulator Housing Attaching Bolt 10 N m 89 in Ib M6 x 1 0 x 14 5 mm 2 Required Copyright O 2011 ATSG Figure 136 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Technical Service Information 5 CLUTCH C3 ASSEMBLY EXPLODED VIEW 575 4 5 CLUTCH C3 BACKING PLATE RETAINING SNAP RING 580 4 5 CLUTCH C3 PISTON RETURN SPRING ASSEMBLY 576 4 5 CLUTCH C3 BACKING PLATE SELECTIVE 581 4 5 CLUTCH C3 PISTON INNER O RING SEAL 577 4 5 CLUTCH C3 LINED PLATE 4 REQUIRED 582 4 5 CLUTCH C3 PISTON ASSEMBLY 578 4 5 CLUTCH C3 STEEL PLATE 4 REQUIRED 583 4 5 CLUTCH C3 PISTON OUTER O RING SEAL C3 579 4 5 CLUTCH PISTON RETURN SPRING RETAINING SNAP RING 584 4 5 CLUTCH C3 DRUM ASSEMBLY Copyright 2011 ATSG Figure 137 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 4 5 Clutch C3 Assembly 1 Disassemble the 4 5 Clutch C3 Assembly using the diagram in Figure 137 as a guide 2 Clean
146. nd lay on the work area for disassembly as shown in Figure 159 14 Remove the three control valve body bolts using an 8 mm socket as shown in Figure 160 15 Lift straight up and remove the rear control valve body assembly as shown in Figure 160 Cont d on page 83 121 MIDDLE CONTROL VALVE BODY ASSEMBLY 122 MIDDLE CONTROL VALVE BODY TO LOWER CONTROL VALVE BODY SEPARATOR PLATE AND GASKETS 123 REAR CONTROL VALVE BODY ASSEMBLY 130 CONTROL VALVE BODY BOLT M5 X 0 8 X 40 MM 1 REQUIRED 132 CONTROL VALVE BODY BOLT M5 X 0 8 X 35 MM 2 REQUIRED 334 PRESSURE TAP DO NOT REMOVE Copyright O 2011 ATSG Figure 160 e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 16 Lift and remove the middle control valve body to lower control valve body separator plate with gaskets away from the middle control valve body assembly as shown in Figure 161 17 Remove the cooler bypass valve and spring the tcc check valve and spring and the five accumulator check valves as shown in Figure 161 18 Lift and remove the front control valve body spacer plate gasket and spacer plate and the front control valve body spacer plate to middle control body gasket as shown in Figure 162 N O N o PA EG 20 ACCUMULATOR CHECK VALVE 44 COOLER BYPASS VALVE 45 COOLER BYPASS VALVE SPRING 46 TCC CHECK VALVE 47 TCC CHECK VALVE SPRING 121 MIDDLE CONTROL VALVE BODY ASSEMBLY 122 MIDDLE CONTROL VALVE
147. nd play measurement is not within transmission using a twisting motion so that the specification choose another selective shim from planetary carrier assembly splines into each ofthe the chart in Figure 230 on page 128 2 Reverse clutches as shown in Figure 223 28 Apply a 3mm 1 8 in bead of sealant GM P N 89020326 or equivalent to the Cont d on page 127 transmission rear case cover and install the cover onto the transaxle as shown in Figure 220 TORQUE ALL BOLTS IN THE 29 the bolts from the case cover and apply a SEQUENCE SHOWN small amount of threadlocker GM P N 12345382 25 N m 18 Ib ft or equivalent to all 12 transmission rear case cover bolts as shown in Figure 220 30 Install 9 M8 x 1 25 x 30mm bolts and hand tighten only as shown in Figure 220 31 Install 2 M8 x 1 25 x 45mm bolts and hand tighten only as shown in Figure 220 32 Install 1 M8 x 1 25 x 48mm bolt and hand tighten only as shown in Figure 220 33 Once the rear case cover bolts have been hand tightened torque each of the twelve bolts to 25 N m 16 Ib ft in the numerical sequence shown in Figure 221 ee Copyright 2011 ATSG 34 Install the 1 2 Reverse internal gear as shown in Fi 221 Figure 222 mm ee 23 Make sure the internal gear thrust bearing assembly doesn t become dislodged as shown in Figure 222 Rear Case Cover Bolts 1 M8 x 1 25 x 30mm 9 Required 2 M8 x 1 25 x 45mm 1 Required 3 M8 x 1 25 x 48mm 2
148. ne with two mechanical sprag clutches to deliver six different gear ratios through the gear sets The gear sets then transfer torque through the differential assembly and then out to the drive axles AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information DESCRIPTION OF GEAR RANGES The Saturn Vue Ion Sedan Chevrolet Equinox and Pontiac Torrent all use a six detent shift quadrant as shown in the diagram in Figure 3 P Park position enables the engine to be started while preventing the vehicle from rolling either backward or forward For safety reasons the vehicles parking brake should be used in addition to the Park position R Reverse enables the vehicle to be operated in a rearward direction N Neutral position enables the engine to start and operate without driving the vehicle If necessary this position should be selected to restart the engine while the vehicle is moving D Drive range should be used for all normal driving conditions for maximum efficiency and fuel economy Drive range allows the transmission to operate in each of the five forward gear ratios Downshifts to a lower gear or higher gear ratio are available for safe passing by depressing the accelerator or by manually selecting a lower gear range with the selector lever SATURN GM SHIFT QUADRANT te Copyright 2011 ATSG Figure 3 ATSG DESCRIPTION OF GEAR RANGES CONT D Intermediate range can be used for conditions
149. necessary 4 Install the Rear Internal Gear Flange into the Rear Internal Gear and install the snap ring as shown in Figure 151 5 Coat the Rear Internal Gear Thrust Bearing with a small amount of Trans Jel and install onto upper side of the Rear Internal Gear Flange as shown in Figure 151 6 Coat the Rear Sun Gear Thrust Bearing Race with a small amount of Trans Jel and install onto the lower side of the Rear Internal Gear Flange as shown in Figure 151 535 REAR INTERNAL GEAR THRUST BEARING ASSEMBLY 536 REAR INTERNAL GEAR 537 REAR SUN GEAR THRUST BEARING RACE 547 REAR INTERNAL GEAR FLANGE 548 REAR INTERNAL GEAR FLANGE RETAINING SNAP RING Copyright O 2011 ATSG Figure 151 Technical Service Information 7 Install the Front Sun Gear into the Front Planet Carrier Assembly and install the retaining snap ring as shown in Figure 152 8 Coat the Front Planet Carrier Thrust Bearing Race and the Front Sun Gear Thrust Bearing with a small amount of Trans Jel and install onto the Front Planet Carrier Assembly and the Front Sun Gear as shown in Figure 152 9 Coat the Rear Sun Gear Thrust Bearing Assembly the Front Sun Gear Thrust Bearing Race and the Input Shaft Thrust Bearing Assembly with a small amount of Trans Jel amp and install onto the Rear sun Gear Assembly as shown in Figure 152 10 Set all Front Planet Carrier and Sun Gear Assembly parts aside for final assembly 538 REAR SUN GEAR THRUST BEARING ASSEMBLY
150. ng Assembly Cont d 10 Install the 1 2 Reverse Piston Return Spring Assembly into the Piston as shown in Figure 131 11 Using SST J 45184 J 23456 and J 23327 or other adequate spring compressing device such as an arbor press compress the 1 2 Reverse Piston Return Spring gently being careful not to bend the spring cage 12 Install the 1 2 Reverse Piston Return Spring Retaining Snap Ring as shown in Figure 131 606 AUTOMATIC TRANSMISSION REAR COVER AND 1 2 REVERSE BRAKE B5 HOUSING ASSEMBLY 618 1 2 REVERSE BRAKE B5 CUSHION APPLY PLATE 619 1 2 REVERSE BRAKE B5 STEEL PLATE 6 Required 620 1 2 REVERSE BRAKE B5 LINED PLATE 6 Required 621 1 2 REVERSE BRAKE B5 BACKING PLATE Selective 622 1 2 REVERSE BRAKE B5 BACKING PLATE RETAINING SNAP RING Copyright 2011 ATSG Figure 132 Technical Service Information 13 Make sure the snap ring is fully seated in the snap ring groove Note All frictions should be soaked in the appropriate ATF for at least 30 minutes prior to installation 14 Install the 1 2 Reverse Brake B5 Cushion Apply Plate into the housing as shown in Figure 132 15 Starting with a Steel Plate and alternating Steel Plates and Lined Plates install the 1 2 Reverse Brake B5 Steel and Lined Plates into the housing as shown in Figure 132 16 Install the 1 2 Reverse Brake B5 Backing Plate as shown in Figure 132 17 Install the 1 2 Reverse Brake B5 Backing Plate Retaining Snap Ring
151. ntiac Torrent are all filled through the dipstick tube located on the side of the transmission by the side pan Refer to Figure 4 for dipstick tube location IMPORTANT NOTE Dexronlll ATF is not compatible with this transmission if DexronIII ATF is used transmission failure may result Use only GM T IV fluid Part No 88900925 or equivalent in this transmission To check fluid level warm transmission temperature to 60 70 C 140 158 F With engine running and selector lever in park remove the dipstick retaining bolt as shown in Figure 4 Next remove the dipstick and wipe clean then insert dipstick into the case and remove quickly Check to make sure fluid 15 at the correct level on the stick as shown in Figure 4 Copyright 2011 ATSG Figure 4 AUTOMATIC TRANSMISSION SERVICE GROUP PGATSG ELECTRICAL COMPONENTS Emergency Mode Operation If for any reason the entire electronic control system of the transmission becomes disabled all five of the shift solenoid valves will be de energized turned OFF This Emergency Mode operating state of the solenoids forces the transmission to operate in fifth gear regardless of other vehicle operating conditions when the gear selector is in a forward drive range Also in Emergency Mode the TCC lock up pressure control solenoid valve is turned OFF in order to prevent TCC apply This allows the vehicle to be operated safely despite the disabled electronic controls until th
152. o the pump assembly and carefully install the fluid pump into the transmission as shown in Figure 245 Use care when installing the fluid pump assembly so that the second clutch B2 sprag assembly does not become dislodged during the installation of the fluid pump 85 Lightly press the fluid pump into the transmission case so that the pump is fully seated in place as shown in Figure 245 86 Install the eight MS x 1 25 x 28 mm fluid pump to case assembly bolts and hand tighten as shown in Copyright 2011 ATSG Figure 246 y 87 Torque the eight M8 x 1 25 x 28 mm fluid pump to Figure 245 case bolts to 25 Nm 18 Ib ft and in the sequence shown in Figure 246 TORQUE ALL BOLTS IN THE 88 Rotate the transmission and install the two case SEQUENCE SHOWN TO fluid passage seals into the transmission as shown 25 N m 16 Ib ft in Figure 247 em TN Cont d on page 133 TOROUE ALL BOLTS IN THE SEOUENCE SHOWN TO 29 Nom 21 lb ft p L He Sn ae d Hrs Mo ET T vi RT SEE CU 4 PSA Y Copy Copyright O 2011 ATSG b tT Copyright 2011 ATSG Figure 244 Figure 247 152 AUTOMATIC TRANSMISSION SERVICE GROUP Dr e e e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 89 Install a new o ring onto the transmission wiring harness assembly and coat the o ring with a small amount of Trans Jel as shown in Figure 248 90 Install the transmission wiring harness assembl
153. og og dep R Reverse fom opf on On og og og og Note 1 CONSULT II indicates 5th 2 Reverse gear ratio difference Gear ratio 3 342 3 3rd gear ratio difference Gear ratio 2 301 of C Off Off Off Off Off Ku AUTOMATIC TRANSMISSION SERVICE GROUP 157 PAATSG Technical Service Information BEARING AND RACE LOCATIONS AND SPECIFICATIONS 2 2 MM Nk Jr ENN Vum d La ja lt ex 7 L ai T mE Y oi TA om Ei Ei E Copyright 2011 ATSG Figure 273 158 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information BEARING AND RACE LOCATIONS AND SPECIFICATIONS Outer Diameter Inner Diameter COMPONENT Specification Specification Item mm in mm in 596 1 2 Reverse Internal Gear Shim 57 70 mm 2 272 in 37 00 mm 1 457 in 537 Rear Sun Gear Thrust Bearing Race Front 74 00 mm 2 913 in 53 00 mm 2 087 in 538 Rear Sun Gear Thrust Bearing 65 00 mm 2 559 in 50 00 mm 1 968 in 540 Input Shaft Thrust Bearing 43 40 mm 1 709 in 22 05 mm 0 868 in 226 Coast Clutch Hub Thrust Washer Front 568 Forward Clutch Housing Thrust Bearing Race Front 41 00 mm 7 614 in 13 50 mm 0 531 in T Copyright O 2011 ATSG Figure 274 No AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FASTENER
154. on Shift Lock P0931 Solenoid P Position Shift Lock Oscillating Engine RPM Signal Too Low Short to Ground Signal Too High Short to Voltage NOTE CODES IN BOLD TYPE ARE FOR 2002 LATER MODELS Copyright 2011 ATSG Figure 281 166 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information DIAGNOSTIC TROUBLE CODES DTC S NISSAN P CODES DIAGNOSTIC TROUBLE CODE DESCRIPTION P0500 P0613 P0705 P0710 P0711 P0717 P0722 P0726 P0731 P0732 P0733 P0734 P0735 P0744 P0745 P0750 P0755 P0760 P0762 P0765 P0770 P0775 P0780 P0795 P0797 P0826 P0882 P1726 U1000 Vehicle Speed Sensor Circuit Meter TCM Processor PARK NEUTRAL Position Switch Sensor Circuit Automatic Transmission Fluid Temperature Sensor Circuit Open or Short Circuit Automatic Transmission Fluid Temperature Sensor Performance No Signal Voltage Change Turbine Sensor Circuit Vehicle Speed Sensor Circuit A T Engine Speed Input Signal Circuit Performance A T First Gear Function Gear Ratio Error in First A T Second Gear Function Gear Ratio Error in Second A T Third Gear Function Gear Ratio Error in Third A T Fourth Gear Function Gear Ratio Error in Fourth A T Fifth Gear Function Gear Ratio Error in Fifth A T Torque Converter Clutch S V Function TCC Performance or Stuck Off Pressure Control Solenoid A Line Pressure Solenoid SLT Circuit Failure Shift Solenoid A Solenoid S1 Circuit Failure Shift Sol
155. on page 130 retaining bolt as shown in Figure 232 53 Torque the retaining bolt to 70 N m 89 in Ib 54 Install the parking pawl actuating bracket and the parking pawl lever as shown in Figure 233 55 Install the parking pawl retaining shaft and the retaining shaft return spring with the spring holding the parking pawl lever against the actuating bracket as shown in Figure 234 56 Install the manual valve detent lever spring as shown in Figure 235 57 Install the 14 mm and the 16 7 mm manual valve detent lever spring retaining bolts as shown in Figure 235 a We 58 Torque the 14 mm bolt to 5 Nm 44 in Ib as 4 Copyright 2011 ATSG shown in Figure 235 Figure 233 lg Copyright Mi ore ode Figure 231 Figure 234 Torque the retaining E ee bolt to mear 7 10 N m 89 in Ib a da is Copyright 3011 Tm n be Copyright Figure 232 mE Figure 235 AUTOMATIC TRANSMISSION SERVICE GROUP 129 ARTS TRANSAXLE FINAL ASSEMBLY Cont d 60 Install the parking pawl actuator rod into the transmission as shown in Figure 236 61 Install the manual valve detent lever into the case as shown in Figure 236 62 Rotate the manual valve detent lever forward and engage the parking pawl actuator rod into the detent lever Lift upward on the manual valve detent spring and slide the manual valve detent lever into place in the transmission as shown in Figure 236 Be careful not to damage the linkage s
156. over attaching bolts then remove the control valve body cover as shown in Figure 24 Figure 24 Technical Service Information 16 Remove the control valve body fluid passage cover attaching bolts as shown in Figure 25 17 Remove the control valve body fluid passage cover and the control valve body fluid passage cover gasket as shown in Figure 25 18 Carefully depress the locking tab for each of the five shift solenoids S1 S2 S3 S4 and S5 then remove the connector from the five solenoids as shown in Figure 25 19 Using a small screwdriver or scribe carefully depress the locking tab for each of the three linear solenoids SLS SLT and SLU then remove the connector from the three solenoids as shown in Figure 25 20 Remove the ATF temperature sensor hold down retainer attaching bolt as shown in Figure 25 21 Remove the ATF temperature sensor hold down retainer and gently lift the ATF temperature sensor upward with a twisting motion and carefully move the harness away from the control valve body assembly as shown in Figure 25 22 Remove and discard the ATF temperature sensor o ring Cont d on page 21 d a m i NE EER S j em Na Y T sc D ni j j ATF TEMP P 30 SENSOR Q di CONTROL VB FLUID PASSAGE COVER F E ETE is Copyright 2011 ATSG Figure 25 AUTOMATIC TRANSMISSION SERVICE GROUP Figure 27 AUTOMATIC TRANSMISSION SERVI
157. parts thoroughly and dry with compressed air 3 Inspect all carrier gear parts and replace as necessary A Reassemble the 1 2 Reverse Carrier Gear Assembly using the diagram in Figure 149 as a guide 5 Coat the washers bearings and selective race with a small amount of Trans Jel to keep them in place for assembly 6 Set the 1 2 Reverse Carrier Gear Assembly aside for final assembly AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information FRONT PLANET CARRIER AND SUN GEAR ASSEMBLY EXPLODED VIEW 539 540 535 REAR INTERNAL GEAR THRUST BEARING ASSEMBLY 542 FRONT PLANET CARRIER ASSEMBLY 536 REAR INTERNAL GEAR 543 FRONT PLANET CARRIER THRUST BEARING RACE 537 REAR SUN GEAR THRUST BEARING RACE 544 FRONT SUN GEAR 538 REAR SUN GEAR THRUST BEARING ASSEMBLY 545 FRONT SUN GEAR THRUST BEARING ASSEMBLY 539 REAR SUN GEAR ASSEMBLY 546 FRONT SUN GEAR THRUST BEARING RACE 540 INPUT SHAFT THRUST BEARING ASSEMBLY 547 REAR INTERNAL GEAR FLANGE 541 FRONT SUN GEAR RETAINING SNAP RING 548 REAR INTERNAL GEAR FLANGE RETAINING SNAP RING Figure 150 AUTOMATIC TRANSMISSION SERVICE GROUP PAATSG Front Planet Carrier and Sun Gear Assembly 1 Disassemble the Front Planet Carrier and Sun Gear Assembly using the diagram in Figure 150 as a guide 2 Clean all Front Planet Carrier and Sun Gear Assembly parts thoroughly and dry with compressed air 3 lnspect all Front Planet Carrier and Sun Gear parts and replace as
158. put Shaft Speed ISS Sensor LL gt 10MOhms 20 C 68 F Output Shaft Speed OSS Sensor gt 10M Ohms 20 C 68 F Transaxle Case Connector Face View Vehicle Harness Connector Face View Copyright 2011 ATSG Figure 17 AUTOMATIC TRANSMISSION SERVICE GROUP ARTS EXTERNAL ELECTRONIC COMPONENTS Throttle Position TP Sensor The ECM monitors the variable voltage signal from the TP sensor to calculate throttle angle These inputs are then sent over the CAN bus to the TCM to determine the appropriate line pressure shift pattern and TCC apply and release for the transaxle In general with greater throttle angle upshift speeds and line pressure will both increase Manifold Absolute Pressure MAP Sensor The MAP sensor changes relative to intake manifold pressure which results from changes in engine load and speed These changes are converted into a voltage signal which is monitored by the ECM and transmitted over the CAN bus to the TCM to assist in adjusting line pressure and shift timing Engine Coolant Temp ECT Sensor The ECM monitors the variable resistance signal from this sensor to determine engine coolant temperature When the engine is cold resistance is high and when the engine is hot resistance through the sensor is low The ECM then transmits this information over the CAN bus to the TCM where it is used to prevent TCC apply when the engine temp is below approximately 20 C 68 F Techni
159. racket 180 degrees will position the solenoids so that the passages are misaligned or blocked rendering the solenoids useless causing harsh engagements and shifting Refer to the diagrams in Figure 266 and Figure 267 This is much more difficult to do with the 3rd design bracket but is possible with some extra effort It is not uncommon for the internal wire connectors to be cross connected on to an incorrect solenoid This seems to happen most often with the S1 and S3 solenoids The internal harness connector colors do not necessarily match the solenoid connector colors It is best to note wire colors and or tag the internal harness connectors at their correct location upon initial dis assembly for future reference If this is not possible then we would recommended to use the wire color and referto the chart provided in Figure 268 SERVICE INFORMATION INTERCHANGE Itisarecommended practice to use the C stamp valve bodies on earlier vehicles that may have had a B A or NO ID stamp valve body installed when using the C stamp valve body it may be necessary to use the late internal wiring harness because ofthe difference between the connector locations of the two linear solenoids It may also be necessary to have the vehicle re flashed with the latest PCM software updates and also have the adapts reset The shift solenoid S2 may be interchanged as well as long as the correct open closed state solenoid 1s utilized In other wor
160. rag F2 Assembly as shown in Figure 145 11 Coat the Front Internal Gear Thrust Bearing Race with a small amount of Trans Jel and place it onto the Front Internal Gear and Low Clutch Sprag F2 Assembly as shown in Figure 145 Check the operation fo the Low Clutch Sprag F2 12 Assembly as shown in Figure 146 The Low Clutch Sprag F2 Inner Race must Rotate Counter Clockwise and Lock Clockwise While holding the Front Internal Gear the Low Clutch Sprag F2 Inner Race Must Rotate Counter Clockwise in the Direction of the Arrow and Lock Clockwise 25 FRONT INTERNAL GEAR AND LOW CLUTCH SPRAG F2 ASSEMBLY 519 FRONT INTERNAL GEAR THRUST BEARING ASSEMBLY 530 FRONT INTERNAL GEAR THRUST BEARING ASSEMBLY RACE Copyright 2011 ATSG Copyright 2011 ATSG Figure 145 Figure 146 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG 56 THIRD GEAR BAND B4 SERVO PISTON RETURN SPRING 57 THIRD GEAR BAND B4 SERVO PISTON ASSEMBLY SELECTIVE APPLY PINS 58 THIRD GEAR BAND B4 SERVO PISTON AND COVER O RING SEALS 3 REQUIRED 59 THIRD GEAR BAND B4 SERVO PISTON COVER 60 THIRD GEAR BAND B4 SERVO PISTON COVER RETAINING SNAP RING Copyright O 2011 ATSG Figure 147 Technical Service Information Third Gear Band B4 Servo Piston Assembly 1 Disassemble the Third Gear Band B4 Servo Piston Assembly using the diagram in Figure 147 as a guide 2 Clean all Third Gear Band
161. rd as shown in Figure 252 Install the ATF temperature sensor hold down 100 bracket and the one M6 x 1 0 x 55 mm bolt and torque the bolt to 10 Nm 89 in Ib as shown in Figure 252 TORQUE ALL BOLTS IN THE SEQUENCE SHOWN TO 10 N m 89 in Ib Copyright O 2011 ATSG Figure 251 Technical Service Information 101 Install the five shift solenoid connectors S1 S2 S3 S4 and S5 as shown in Figure 252 102 Make sure the connectors are secure and the locking tabs lock into place 103 Install the three linear solenoid connectors SLS SLT and SLU as shown in Figure 252 104 Make sure the connectors are secure and the locking tabs lock into place Cont d on page 135 WIRE ees a BLUE OR GREEN PURPLE OR RED GREEN OR RED E ATF TEMP NE SENSOR AN CONTROL VB FLUID I IR PASSAGE COVER F s i Uu o A Copyright 2011 ATSG Figure 252 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d 105 Apply a 3 mm 1 8 in bead of sealant GM P N 107 Install a new o ring seal onto the output sensor 89020326 or equivalent to the mating surface of and coat the o ring with a small amount of Trans the control valve body cover Jel as shown in Figure 254 106 Apply threadlocker GM P N 12345382 or 108 Install the output sensor into the transmission case equivalent to each attaching bolt then install the using a twisting motion while carefully pushing nine 8 x
162. rect C2 clutch housing thrust bearing and thrust bearing race as shown in Figure 53 82 Remove the forward C1 and direct C2 clutch housing as shown in Figure 53 and set aside for cleaning and component rebuild 83 Remove the input shaft thrust bearing assembly as shown in Figure 54 84 Remove the rear sun gear assembly and the rear sun gear thrust bearing assembly as shown in Figure 54 85 Remove the rear sun gear thrust bearing race as shown in Figure 55 86 Remove the front sun gear thrust bearing race and front sun gear thrust bearing assembly as shown in Figure 55 Tap here gently to loosen converter housing v Copyright 2011 ATSG Figure 53 Technical Service Information 87 Remove the rear internal gear assembly as shown in Figure 55 88 Remove the rear internal gear thrust bearing assembly as shown in Figure 55 89 Remove the front planet carrier thrust bearing race as shown in Figure 56 90 Remove the front planet carrier and sun gear assembly as shown in Figure 56 Cont d on page 28 Figure 56 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG TRANSAXLE DISASSEMBLY CONT D 91 Using a screwdriver remove the low and reverse clutch snap ring as shown in Figure 57 92 Remove the low and reverse clutch upper backing plate the lined and steel plates and the lower backing plate as shown in Figure 57 93 Remove the front internal gear thrust bearing assembly as shown in Figure 58 94 Remove the front in
163. ror P0751 TCM 000B Shift Solenoid S1 Solenoid Performance Hydraulic Malfunction TCM 0118 Line Pressure Solenoid SLT Signal Too Low Short to Ground Permanent Error P0753 i P0974 TCM 0001 Shift Solenoid S1 Signal Too High Short to Voltage P0753 TCM 0002 Shift Solenoid S1 Signal Missing Resistance Too High or Open Circuit dues TCM 0003 Shift Solenoid SI Signal Too Low Short to Ground GE TCM 0118 Line Pressure Solenoid SLT Signal Too Low Intermittent Error P0756 TCM 000C Shift Solenoid S2 Solenoid Performance Hydraulic Malfunction SE TCM 0007 Shift Solenoid S2 Signal Too High Short to Voltage P0758 TCM 0008 Shift Solenoid S2 Signal Missing Resistance Too High or Open Circuit P0758 TCM 0009 Shift Solenoid S2 Signal Too Low Short to Ground P0762 TCM 0115 Shift Solenoid S3 Solenoid Performance Hydraulic Malfunction Soe TCM 0101 Shift Solenoid S3 Signal Too High Short to Voltage P0763 TCM 0102 Shift Solenoid S3 Signal Missing Resistance Too High or Open Circuit TCM 0103 Shift Solenoid S3 Signal Too Low Short to Ground NOTE CODES IN BOLD TYPE ARE FOR 2002 LATER MODELS Copyright 2011 ATSG Figure 280 AUTOMATIC TRANSMISSION SERVICE GROUP 16 ATSG Technical Service Information DIAGNOSTIC TROUBLE CODES DTC S VOLVO VOLVO DIAGNOSTIC TROUBLE P CODES FAULT DESCRIPTION OEM CODES CODE DTC DESCRIPTION SE TCM 0107 Shift Solenoid S4 Signal Too High Short
164. rts with no automatic shifting at all A cause of 5th gear starts in D range with only 2nd gear available when Low range is manually selected may be due to a fault condition being detected and the TCM is in a Protection Mode This may also bereferred to as a Fail Safe or Limp In Mode Other shift characteristics such as 2nd gear starts delayed shifts or sudden downshifts may be normal operation dependant upon factors related to temperature or current driving conditions To correct the cause ofa vehicle determined to be in Protection Mode the fault code s must be retrieved with a capable scan tool and the related failure that caused the fault to be stored must be successfully repaired before the transaxle will resume normal operation Delayed shifts sudden downshifts when pulling a load climbing or descending a grade and a 2nd gear start at times while driving in heavy stop and go city traffic may all be perceived as erratic shifting if you or your customer are not aware of the various special operating modes Your customer may be used to Normal Mode and they may have noticed Cold Mode operation however other special operating modes don t always show up very often and may seem to be an intermittent problem These special modes can vary with the manufacturer Refer to the following charts for a description of operational characteristics while driving with certain special operating mode strategies AUTOMATIC TRANSMISSION SERVICE GROUP 151 e A
165. saxle can be disassembled quite easily on a suitable workbench without the aid of any holding fixture for rotation 3 Place the transmission onto a suitable work bench or appropriate holding fixture 4 Using a small screwdriver bend the tabs of the park neutral switch locking washer away from the park neutral switch lock nut 5 Remove the park neutral switch lock nut the locking washer and the flat washer as shown in Figure 20 6 Remove the park neutral switch bolt the stud and the flat washers as shown in Figure 20 7 Remove the park neutral position switch by lifting straight up as shown in Figure 20 8 Remove the output speed sensor bolt then carefully remove the output speed sensor with a twisting motion as shown in Figure 21 9 Remove and then discard the output speed sensor o ring 10 Remove the input speed sensor bolt then carefully remove the input speed sensor with a twisting motion as shown in Figure 22 11 Remove and discard the input speed sensor o ring NOTE Use care when removing the speed sensors to avoid damage Cont d on page 20 Figure 22 B ARTS TRANSAXLE DISASSEMBLY CONT D 12 Remove the transmission fluid level indicator retaining bolt as shown in Figure 23 13 Carefully remove the transmission fluid level indicator using a twisting motion and lift straight up as shown in Figure 23 14 Remove and discard the transmission fluid level indicator o ring 15 Remove the nine control valve body c
166. should be marked before Cont d on page 89 removal to ensure the retainer is relocated in the factory specified setting FRONT CONTROL VALVE BODY EXPLODED VIEW 1 FRONT CONTROL VALVE BODY ASSEMBLY 12 FORWARD CLUTCH C1 CONTROL VALVE 8 BORE PLUG RETAINER 4 3 2 X 5X 10mm 13 NEUTRAL RELAY VALVE 9 BORE PLUG 4 14 NEUTRAL RELAY VALVE SPRING 10 SOLENOID MODULATOR VALVE SPRING 15 2ND COAST B1 CONTROL VALVE SPRING 11 SOLENOID MODULATOR VALVE 16 2ND COAST B1 CONTROL VALVE Copyright 2011 ATSG Figure 167 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information COMPONENT REBUILD Control Valve Body Assembly Cont d 38 Install the cooler bypass valve spring and the cooler 40 Align the bolt holes in the separator plate with the bypass valve the TCC check valve spring and the bolt holes in the middle control valve body then TCC check valve and the five accumulator check lower the rear control valve body onto the separator valves into the middle control valve body assembly plate and thread the three control valve body as shown nm Figure 168 attaching bolts and hand tighten only as shown in 39 Install the middle control valve body assembly to Figure 169 lower control valve body separator plate and gaskets onto the middle control valve body as shown in Figure 168 121 MIDDLE CONTROL VALVE BODY ASSEMBLY 20 ACCUMULATOR CHECK VALVE 122 MIDDLE CONTROL VALVE BODY TO LOWER CONTROL 44 COOLER BYPASS VAL
167. st eel fem EN ts LL Jee Ea ere peas pom fem fro x pe one pe LOW mm SHIFT SOLENOID APPLICATION CHART GEAR Park Reverse Reverse Neutral Drive Drive Drive Drive Drive Emer Int Int Int Low Low OS Inhibit 1st 2nd 3rd 4th Sth Mode 1st 2nd 3rd 1 E B 2nd REVERSE 1ST SOLENOID OFF OFF ON OFF OFF OFF OFF OFF ON OFF 51 2 3 3 4 SOLENOID OFF OFF OFF OFF ON ON OFF ON S2 1 2 2 3 REVERSE SOLENOID ON OFF OFF ON ON ON OFF OFF OFF ON ON ON ON ON S3 3 4 4 5 SOLENOID OFF OFF OFF OFF OFF ON ON ON OFF OFF OFF ON OFF OFF S4 REVERSE SOLENOID ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF SS NOTE If vehicle speed is detected above 7km h 4mph the TCM commands the solenoids to inhibit reverse Copyright 2011 ATSG Figure 2 4 AUTOMATIC TRANSMISSION SERVICE GROUP ATSG TRANSMISSION GENERAL DESCRIPTION The AF23 33 5 1s a fully automatic electronically controlled five speed front wheel drive transmission consisting primarily of a four element torque converter three planetary gear sets friction and mechanical clutches and a hydraulic pressure control system The four element torque converter contains a pump a turbine a pressure plate which is splined to the turbine and a stator assembly The torque converter acts as a fluid coupling device to smoothly transmit power from the engine to the transmission It also hydraulical
168. t controls the apply and release of the torque converter clutch the second clutch B2 and the Low Reverse clutch B3 during Low range based on current flow through its coil windings This solenoid is Pulse Width Modulated PWM and operates at a fixed frequency of 300 Hz cycles per second and from 0 0 to 1 1 amps As the current flow is increased the pressure control to TCC lock up control pressure 1s increased As current flow is decreased the pressure control to TCC lock up control pressure is decreased as shown in Figure 14 If a total electronic failure is encountered the torque converter clutch apply will be inhibited and will set DTC P0966 or P0967 in the TCM memory AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Shift Pressure Control Solenoid SLS Normally Open SPOOL SPOOL PLUNGER VALVE VALVE SPRING PRESSURE PRESSURE SUPPLY CONTROL SOLENOID SHIFT MODULATOR CONTROL ELECTRICAL CONNECTOR Copyright 2011 ATSG Figure 13 TCC Pressure Control Solenoid SLU Normally Closed PRESSURE PRESSURE CONTROL SUPPLY PLUNGER LOCK UP SOLENOID CONTROL MODULATOR SPOOL VALVE SPRING ELECTRICAL CONNECTOR Copyright 2011 ATSG Figure 14 e ATSG Technical Service Information ELECTRICAL COMPONENTS Cont d Transaxle CaseConnector Identification The 14 way transaxle case connector is actually part of the internal wiring harness assembly as shown in Figure 5 We
169. ternal gear assembly as shown in Figure 58 95 Remove the front internal gear thrust bearing assembly and the front internal gear thrust washer race located on the back side of the front internal gear as shown in Figure 58 96 Using a screwdriver remove the low and reverse clutch piston return spring retaining snap ring as shown in Figure 59 97 Remove the low and reverse clutch piston return spring as shown in Figure 59 98 Remove the low and reverse clutch piston as shown in Figure 59 P OH E Copyright O Figure 57 Figure 58 Technical Service Information 99 Remove and discard the low and reverse clutch piston o rings 100 Remove the output gear assembly retaining snap ring and remove the output gear assembly from the case as shown in Figure 60 101 Remove the lube pipe hold down bracket retaining bolt the hold down bracket and tube as shown in Figure 61 Cont d on page 29 r pec H D d oam e GR M P Copyright 2 Figure 59 Copyright 2011 ATSG Figure 61 AUTOMATIC TRANSMISSION SERVICE GROUP e ATSG Technical Service Information TORQUE CONVERTER HOUSING ASSEMBLY EXPLODED VIEW m 805 806 803 M 3 810 801 816 OW 8n n J D 809 821 C O eA es D 817 807 808 800 O AN 809 AUTOMATIC TRANSMISSION CASE PLUG 820 M18 x 1 5 x 10 5 1 Required 819 810 AUTOMATIC TRANSMISSION CASE PLUG UNF 5 16 24 2A 1 Requ
170. ton fully applied with compressed air make a mark on the servo piston pin This is Mark 2 4 Take a measurement between Mark 1 and Mark 2 this distance 1s Measurement A Using Measurement A determine whether the overall servo travel is within the specifications indicated in the chart on Page 75 Figure 148 If servo travel is not within specification select a different length pin to obtain specified servo travel F Copyright 2011 ATSG Copyright O 2011 ATSG Figure 225 Figure 227 AUTOMATIC TRANSMISSION SERVICE GROUP 127 e ATSG Technical Service Information TRANSAXLE FINAL ASSEMBLY Cont d AA Using Universal Clamp Press J 45053 or other adequate puller device attach the clamp and carefully install the front differential assembly transfer drive gear assembly into the transmission case as shown in Figure 228 It will be necessary to twist the transfer drive gear assembly in order to spline with all the frictions of the 4 5 clutch C3 drum 45 Install the front differential transfer drive gear thrust washer selective and the transfer drive gear bearing assembly Refer to Figure 228 46 Place a straight edge across the transfer drive gear bearing and using a feeler gage take a clearance measurement between the straight edge and the case Refer to Figure 229 47 The measurement specification should be 7 269 1 645mm 0 050 0 065 in EE A F Ken Copyright 2011 ATSG Figure 228 i l MEASUREMENT SPECIFI
171. using the diagram in Figure 208 as a reference If any wear or damage is observed replace the output gear assembly 3 Carefully install the lube pipe into the transaxle case using a soft faced mallet and then install the lube pipe hold down bracket and hold down bracket retaining bolt as shown in Figure 209 4 Torque the hold down bracket retaining bolt to 5 N m 44 in Ib as shown in Figure 209 5 Install the output gear assembly into the transaxle case and install the output gear assembly retaining snap ring as shown in Figure 210 6 Make sure the retaining snap ring 1s fully seated in the output gear assembly Cont d on page 124 s Torque Bolt to 47 Nm 44 in Ib Tea 4 _ Copyright 2011 ATSG Figure 210 AUTOMATIC TRANSMISSION SERVICE GROUP 123 PAATSG TRANSAXLE FINAL ASSEMBLY Cont d 7 Install the L R brake B3 piston into the transaxle case by pressing downward and tap lightly with the handle of a screwdriver if necessary as shown in Figure 211 8 Install the L R Brake B3 piston return spring and the return spring retaining snap ring as shown in Figure 211 9 Make sure the snap ring 1s fully seated in the snap ring groove inthe case as shown 1 Figure 211 10 Install the front internal gear assembly onto the splines of the output gear assembly as shown in Figure 212 11 Install the front internal gear thrust bearing assembly onto the front internal gear and ho
172. where it may be desirable to use only three gear ratios These conditions include towing a trailer and driving in hilly or mountainous terrain This range is also helpful for engine braking when descending slight grades Upshifts and downshifts are the same as in the Drive range for first second and third gears except that the transmission 1s prevented from shifting above third gear Intermediate range can be selected at any vehicle speed however the transmission will downshift into third gear only if vehicle speed is low enough so that the engine will not over rev Such conditions determined by calibration of the TCM L Low range adds more performance for congested traffic and hilly mountainous terrain It has the same starting ratio first gear as Drive and Intermediate ranges but prevents the transmission from shifting above second gear Therefore Low range can be used to retain second gear for acceleration and engine braking as desired Low range can be selected at any vehicle speed however the transmission will downshift to second gear only if vehicle speed is low enough so that the engine will not over rev Such conditions determined by calibration of the TCM This range is particularly beneficial for maintaining maximum engine braking effect when descending steep grades Technical Service Information FLUID REQUIREMENTS LEVEL CHECKING The AF23 33 5 transmission in the Saturn Vue and Ion the Chevrolet Equinox and the Po
173. will resume when accelerator is moved less quickly Extreme Extreme Mode is another way of saying wide open throttle or kick down The control Mode module will selectthe lowest possible gear forthe vehicle speed at full throttle Winter Mode is obtained by using the W button on the top panel of the gear selector assembly An indicator lamp in the instrument cluster will be lit when Winter Mode is selected In D range the transaxle starts in 3rd gear to provide maximum traction on Winter slippery surfaces and automatically shifts between 3rd 4th and 5th gears In 4 range the Mode transaxle starts in 3rd and automatically shifts to 4th gear earlier than Economy Mode in D range and Sth gear is locked out In 3 range the transaxle starts in 3rd and stays in 3rd InL range the transaxle starts in 2nd gear and stays in 2nd gear At wide open throttle in Winter Mode the transaxle uses all gears for maximum performance Catalytic This function allows the engine to reach proper operating temperature more quickly by Converter preventing converter clutch lock up and significantly delaying the 1 2 and the 2 3 up Start shifts when the engine is cold This 1s anormal function Temperature If the transmission oil temperature rises excessively as a result of a heavy load with high Controlled ambient temperature conditions the converter clutch will be applied to reduce the heat Lock Up generated through torque multiplication Lock up 1s inhibited
174. y into the transmission using a twisting motion while pushing carefully downward as shown in Figure 248 91 While holding the control valve body assembly install the manual valve link into the manual valve shift detent lever as shown in Figure 249 92 Install the control valve body assembly onto the transmission case being careful to not pinch or damage the transmission wiring harness 93 Install the two M6 x 1 0 x 16 mm 34 bolts and hand tighten as shown in Figure 250 94 Install the two M6 x 1 0 x 28 mm 35 bolts and hand tighten as shown in Figure 250 95 Install the two M6 x 1 0 x 55 mm 37 bolts and hand tighten as shown in Figure 250 Cont d on page 134 Qd Copyright 5 Figure 248 Figure 250 AUTOMATIC TRANSMISSION SERVICE GROUP 153 ATSG TRANSAXLE FINAL ASSEMBLY Cont d 96 Torque the six control valve body assembly attaching bolts to 0 Nm 89 in 1 in the sequence shown in Figure 251 97 Install a new control valve body fluid passage cover gasket and the control valve body fluid passage cover as shown in Figure 252 98 Install the two M6 x 1 0 x 50 mm control valve body fluid passage cover retaining bolts and torque the bolts to 70 N m 89 in Ib as shown in Figure 252 99 Install a new o ring seal onto the ATF temperature sensor and coat the o ring with a small amount of Trans Jel then install the ATF temperature sensor into the valve body with a twisting motion while pushing downwa

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