Win A Harley-Davidson® Super Glide in TransTec`s 20th
Contents
1. 3rd 1st 2nd am aw 5 The valve body accumulator cover plates for Volvo versions use gaskets bonded to the plates while Opel uses separate plates and gaskets 6 Don t forget these little seals hiding beneath the valve body Leave these out and your day may be ruined The left seal is for lube to the transfer gear the one on the right is for low and reverse apply 7 Careful Early units take cast iron rings here Late units use Teflon rings riding on a steel sleeve If you use the late seals on the early cover the Teflon rings will destroy the aluminum cover You can imagine how pleased a customer will be with a car that has no forward range The forward accumu lator piston also resides in the rear cover 8 If you are counting along there are now six little seals like this to ruin your day These seal the forward and direct clutch apply fluid as well as lube fluid to the planetary assembly 9 Here is another one of those easily missed ruined my day parts This small Vespel ring seals lube oil for the forward direct drum pilot shaft bearing Be sure to check this drum carefully it tends to crack around the weld leaving you with no forward again 10 Intermediate sprag rotation inner hub locks counter clockwise and free wheels clockwise 11 Low sprag rotation inner hub freewheels counter clockwise and locks clockwise2. Volume 5 Issue 1 First Quarter 1998 Win A Harley Davidson Super Glide in TransTec s 20th Anniversary Head Out On The Highway Give Away The next TransTec transmission rebuild kit you open may qualify you to win a new Harley Davidson Super Glide motorcycle It s all part of TransTec s Head Out On The High way contest celebrating the company s 20th anniversary of supplying transmission professionals with rebuild kits No purchase is necessary but you must be a professional transmission technician or shop owner to participate Official entry forms can be found in TransTec transmission kits with a date In this issue e Our Troubleshooter feature article provides insight into Aisin Warner 5040 transaxles See page 3 e Win a Harley Davidson Super Glide in TransTec s 20th anniver sary Head Out On The Highway contest See cover article e A604 606 reaction support rings made from Vespel See cover article e GM changes color of 4L60 E pump cover filter screen See page 2 e New Vamac lathe cut seal intro duced for GM pump See page 2 e Stator support shaft O ring now available for Mitsubishi KM and F4A WAA series with lock up converter See page 6 e Running change made to 4R70W valve body gaskets See back cover code of A98 to K98 If you open a TransTec kit that doesn t contain an official entry form you can still enter the contest Simply fill out a postcard after reviewin
3. 12 Bet you thought you were through with these pesky seals This one is between the case halves and seals lube oil for the differential bearings 13 Located in the converter housing case half is another easily missed ruined my day sealing ring This one seals lube oil for the planetary gear sets This Vespel ring has a gap that is normal when installed 14 Care must be taken when re assembling the planetaries This photo shows the retaining ring mis positioned The internal ring gear is below the level of the carrier pinions 15 This photo shows the planetary retaining ring correctly installed The internal ring gear is flush with the carrier pinions 16 Underdrive sprag rotation drum assembly freewheels counter clock wise and locks clockwise This photo also shows the underdrive brake band and the underdrive clutches 17 Did you think you were through with those Little parts Leave this anti clunk spring out and you ll be chasing a driveline clunk all day 18 I m hiding Can you find me teases the underdrive brake accumulator 19 The parking pawl assembly plays double duty by also retaining the underdrive brake accumulator assembly Caution This is under spring pressure and may very well pop you in the nose Stator Support Shaft O ring Now Available for Mitsubishi KM and F4A W4A series with Lock up Converter Complaints of a continuously shuddering converter cl
4. the rings in these applications The tests are expected to show that the rings are superior for these applications as well Due to the high RPM capacity of Vespel these rings should be espe cially useful in racing applications gt S e Eo a e S 2 amp o c o e S a Vespel Sealing Rings One of the advantages of the Vespel ring is its ability to seal against an irregular ring groove surface To accom plish this the ring must seat against the side of the ring groove The use of assembly gel or grease especially grease interferes with this seating process 1 Install seal dry or lightly lu bricated with transmission fluid Do NOT use any type of assembly gel or grease 2 Carefully install ring over shaft lands Be careful not to over expand the ring Caution Itis strongly recom mended that assembly lube NOT be used for installation of these sealing rings Comparison of Sealing Ring Material LEAKAGE ml MINUTE 75 TEMPERATURE F 220 Cast Iron Vespel A PTFE Solid NEWS Denny Scher Editor Rebuilder News is dedicated to providing current technical information to the automatic transmission rebuilder Reader s comments suggestions are welcomed Write Editor Rebuilder News P O Box 556 Milan Ohio 44846 0556 1998 Freudenberg NOK General Partnership All rights reserved Repr
5. Support Ring TransTec is proud to announce the first in a series of Vespel brand sealing rings developed exclusively for the aftermarket A joint effort between TransTec and DuPont has produced an A604 606 reaction support ring that features superior sealing at all tempera ture ranges increased longevity and ease of installation Vespel seal rings have been thor oughly tested in the laboratory by DuPont and in the field by Certified Transmissions of Omaha Nebraska and outperformed the OEM metal ring and the 4L80E Teflon ring used by some rebuilders The chart on the next page shows the results of laboratory testing It should be Vespel Sealing Rings continued from front cover noted that all tests were done using new parts This is especially important in the case of the solid Teflon rings which tend to shrink after time This increases the clearance between the ring and drum resulting in more leakage If the test could have been done with seasoned components the results would have been even more dramatic Don t be confused if the kit you re using does not include the metal ring The new Vespel ring P N 21442 replaces the metal ring P N 21051 in all kits and for bulk sales This ring is also used in the A500 for which kits have also been updated As a further bonus this ring will also fit TH400 and 4L80E center supports as well as TH400 front covers We are still in the process of testing
6. dress Service Requested Foma Aftermarket Division
7. g contest rules presented in TransTec advertisements You can also call TransTec s toll free contest hotline at 1 800 852 0340 ext 6405 for contest information The Head Out On The Highway contest inaugurates our 20th year of serving transmission professionals and shop owners noted Dave Gardner president of Freudenberg NOK s Aftermarket Division the company that brings you TransTec kits Our growth and success over the past 20 years is a direct result of their support he added Freudenberg NOK is a supplier of original equipment seals for Harley Davidson Their motorcycles and our kits are both made in America and both known for their quality said David McGee director of aftermarket opera tions Harley Davidson has a lot of appeal with transmission technicians eo from Mransiec added McGee Rebuilders attending our tech seminars frequently wear clothes emblazoned with the Harley logo Awarding some rebuilder or shop owner with a Super Glide has tremen dous appeal especially since we re a supplier for Harley Davidson The next time you re rebuilding with a TransTec kit look for the 20th anniversary Head Out On The Highway contest entry form You may become the proud owner of a brand new Harley Davidson Super Glide The drawing for the motorcycle will be held December 1 1998 Vespel Sealing Rings Deliver Superior Performance in A604 606 Reaction
8. ic hype we re hearing lately Unraveling the Transaxles The 5040 is offered in quite a few different versions Volvo uses the AWS5040LE and the AW5042LE Opel just to be difficult uses different designations Opel calls their units the AF14 AF20 and AF22 There are some differences between Opel and Volvo the most notable being the axle seals Opel uses a GM type seal with a steel stone guard similar to the TH125 Volvo on the other hand uses a typical Japanese rubber coated seal There are some other internal differences but basically they are the same unit The reason for different versions within the same car families is torque capacity Basically the higher the model number the larger the engine and greater number of clutch plates installed in the unit Not Much Info Available One reason we decided to write this article is to address the lack of informa tion available That s also why it took us so long to develop a kit for these transmissions Volvo does not service this transmission they only sell reman units The Volvo factory manual only contains R amp R and electrical informa tion Volvo s parts cataloging was also lacking the only parts you can buy at the Volvo dealer are external items or a whole transmission Most of our information came from Europe Opel does service parts and we were able to obtain a service manual The rest of the information came from disassembling both a Volvo and Opel
9. ission Technician In the early 90s Volvo developed their first front wheel drive vehicle the 850 When it came time to pick a transmission they logically turned to their long time supplier Aisin Warner What Aisin offered was the AWS040LE Volvo was not the first car company to use this transmission Opel has had this unit in production since 1989 in the Calibra and Cavalier Not to be confused with the Chevy Cavalier they re two different cars Coming Soon For you guys that are saying to yourself Who cares I know I ll never work on an Opel and hopefully I can avoid Volvos too Listen up Opel has already arrived in the states The Cadillac Catera is an Opel in Cadillac clothing The Catera is a rear drive vehicle and uses a 4L30E but you get my point For 1998 Saab owned by GM is offering the 9 5 and 9 3 but guess what They re Opels in disguise Both of these are using the front drive Aisin units Rumor has it that in 1999 Saturn will start selling a car based on the Opel Calibra Currently the Calibra also uses the Aisin unit With everyone worried about the world economy auto manufacturers are starting to design cars to be sold worldwide Chances are stuff only seen in other parts of the world will eventually find its way to the states So brace yourself for the invasion of the 5040 we re just beginning to see the tip of the iceburg an appropriate reference with all the Titan
10. ke this opportunity to thank ATP A T R S Ltd in England for the samples the cores and technical information used to write this article and develop the kits for these units 1 The Volvo and Opel versions of this trans use totally different axle seals The Volvo uses the typical Aisin rub ber coated seal while the Opel seal is similar to the metal clad TH125 axle seals 2 The wiring harness for the shift solenoids can be swapped The wire for shift solenoid A SI is black witha shield on both Opel and Volvo units 3 Solenoid identification Top row from left to right Lock up solenoid SL pressure control solenoid STH shift solenoid A S Bottom row left to right Arrow shows retainer end of the PCS shift solenoid B S 4 Accumulator pistons located in the rear valve body have Teflon seals to perform sealing duties Note there are only 3 pistons while the V B housing has 4 bores Identification Left side upper intermediate B lower direct C right side underdrive C Applied Elements B1 Over Run Clutch B2 Intermediate Clutch B3 Low amp Reverse Clutch B4 Underdrive Brake Band C1 Forward Clutch C2 Direct Clutch C3 Underdrive Clutch F1 Intermediate Sprag F2 Low Sprag F3 Underdrive Sprag S1 Shift Solenoid A S2 Shift Solenoid B POSITION Parking Reverse Neutral 1st 2nd 3rd 4th 1st 2nd
11. oduction without prior written permission is prohibited GM Changes Color of Pump Cover Filter Screen General Motors has made a running change in the color of the pump cover line pressure filter on 1982 up TH700 R4 4L60 and 4L60E transaxles Current parts are made from a black plastic resin material which will change to a white plastic resin This is a color change only everything else remains the same The new white pump cover filter will be added to TransTec rebuild kits when stock of the current black part is depleted 15015 80443 Filter TransTec 80443 OEM 8642912 amp 24210086 O ring TransTec 15015 OEM 8642581 New Vamac Lathe Cut Seal Introduced for GM Front Pump The front pump O ring for GM applica tions detailed below changed for the 1997 model year The new seal is made of Vamac which replaces the poly acrylate material previously used Itis easily identified by its pink edge in contrast to the yellow edge of the polyacrylate seal GM Applications 1982 up TH700 R4 4L60 4L60E 1990 up 4L80E TransTec 23503 OEM 24210605 TransTec rebuild kits for these appli cations will contain the new Vamac seal when stock of the previous seal TransTec 25054 OEM 8654716 is depleted The new seal will be available from your local TransTec Distributor Iranslec TROUBLESHOOTER Invasion of the 5040 Aisin Warner s transaxle comes in many disguises By Tony Darr Transm
12. unit and seeing for ourselves The following pages present a photo record Resistance Chart Component Engine Speed RPM Sensor Solenoid A Solenoid B Solenoid Lock Up Remarks Resistance between the solenoid pin and the solenoid cover transmission housing Resistance Q 300 600 10 15 10 15 10 15 Solenoid Pressure Control Resistance between the solenoid pins 2 6 Oil Temperature Sensor Temperature C F 0 43 20 68 40 104 80 176 100 212 150 302 1700 2300 765 1035 340 460 107 143 64 86 23 31 of our efforts Before reviewing the photos there is one other unit I would like to mention There is a smaller version of this puppy running around Aisin Warner downsized this unit and called it the AW6040 Opel of course has to have their own name the AF13 Basically the two units are similar in function the large difference being that the 6040 gets the same job done with one less clutch and one less sprag element The easiest way to tell the two apart is that the servo on the 5040 is on top of the case and in the 6040 it comes in from the bottom of the case You will find this smaller unit in the Suzuki Esteem here in the states Suzuki Baleno overseas Daihatsu Charade and Applause overseas Opel Astra Tigra and Corsa overseas and the Holden Barina SB overseas More on this baby brother next time A Note of Thanks I would like to ta
13. utch have been traced to a deteriorated O ring on the pump stator support shaft Deterioration of this O ring causes converter release fluid pressure loss allowing the clutch to drag causing shudder and premature failure It is advisable to replace the entire assembly However due to the demand an O ring has been designed for this application The O ring TransTec 17842 is made of Viton It will be added to the TransTec gasket seal and overhaul kits for the appropriate Mitsubishi applications Care must be taken when installing this part it is very thin and can be deformed easily Running Change Made to TransTec No 12862 4R70W Valve Body Gaskets OEM No F7AZ 7D100 AA Gasket has 1996 Up a white stripe There has been a running change made to the lower valve body gasket in the 4R70W 1996 up This change involves the hole shown in the illustration and the identifica tion color stripe The hole for the 2 1 exhaust has been enlarged from 200 to 230 in diameter to aid in shift timing The color stripe has been changed from light orange to white This revised gasket will retro fit all previous 1996 up models and will be added to all 4R70W gasket seal kits and overhaul kits when stock on the previous part is Hole depleted enlarged from 200 to 230 TransTechnical Bulletin Trans ec Bulk Rate P O Box 556 U S Postage Paid Milan Ohio 44846 0556 USA Sandusky Ol 44810 Permit 70 Ad
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