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2009TECHNICAL SEMINAROur Goal isYOUR Success!

iIntro2009TECHNICAL SEMINAROur Goal isYOUR Success! 2009 ATRA. All Rights Reserved.

iiIntroTheAutomatic Transmission RebuildersAssociation2400 Latigo AvenueOxnard, CA 93030Phone: (805) 604-2000 Fax: (805) 604-2005http://www.atra.comThis manual has been developed by the Automatic Transmission Rebuilders Association(ATRA) Technical Department to be used by qualified transmission technicians inconjunction with ATRA’s technical seminars. Since the circumstances of its use arebeyond ATRA’s control, ATRA assumes no liability for the use of such information or anydamages incurred through its use and application. Nothing contained in this manual isto be considered contractual or providing some form of warranty on the part of ATRA. Nopart of this program should be construed as recommending any procedure which iscontrary to any vehicle manufacturer’s recommendations. ATRA recommends onlyqualified transmission technicians perform the procedures in this manual.This manual contains copyrighted material belonging to ATRA. No part of this manualmay be reproduced or used in any form or by any means — graphic, electronic ormechanical, including photocopying, recording, electronic or information storage andretrieval — without express written permission from the ATRA Board of Directors.Public exhibition or use of this material for group training or as part of a schoolcurriculum, without express written permission from the ATRA Board of Directors isstrictly prohibited.ATRA and the ATRA logo are registered trademarks of the Automatic TransmissionRebuilders Association.Portions of materials contained herein have been reprinted with permission of GeneralMotors Corporation, Service Technology Group Agreement # 0610228.Portions of materials contained herein have been reprinted with permission of FordMotor Company.Portions of materials contained herein have been reprinted with permission of DaimlerChrysler Corporation. 2009 ATRA. All Rights Reserved.

IntroiiiDennis MaddenChief Executive OfficerCongratulations on attending ATRA’s 2009 Technical Seminar!These days, many shops are devoting more of their time to learning marketing and management techniques; concepts and practices designed to help shops bring more customers in the door.That’s important — we can’t stay in business without customers. But bringing ’em in thedoor is only half the job: It doesn’t mean a thing unless you have the skills and trainingto get ’em back out again.That’s what the ATRA Technical Seminar program is all about: It’s designed to provideyou with the latest information and training, to help you fix today’s transmissionproblems. So you can get ’em out the door again, with their transmissions working likenew. Because that’s what’ll keep ’em coming back again and again.So, on behalf of the ATRA staff and the ATRA Chapters that have worked so hard to putthis program together, I’d like to welcome you, and thank you for doing your part to keepour industry strong. We hope you have a wonderful day, and a terrific learningexperience.Dennis Madden,ATRA, CEO 2009 ATRA. All Rights Reserved.

ivIntroLance WigginsTechnical DirectorThe ATRA technical department is proud to be celebrating another year serving theautomatic transmission repair industry. Many changes have taken place over the years,technical training has become an integral part of today’s transmission repair industry.To that end, ATRA is pleased to present its 2009 Technical Seminar. Packed withcountless hours of research, this year’s seminar will stand out as one of the mostdemanding and useful technical training programs ever developed for this industry.With over 240 pages of up-to-the-minute technical information, the 2009 TechnicalSeminar Manual will remain a valuable resource long after the seminar is just amemory.We’re confident that you’ll find this year’s seminar presentation and technical manualboth informative and profitable. In fact, we’re so sure you’ll be satisfied with what youlearn in this program, we guarantee it!On behalf of the entire ATRA staff, the international board of directors, and all of theATRA members worldwide, we’d like to thank you for your continued support.Lance WigginsATRA Technical Director 2009 ATRA. All Rights Reserved.

vIntroATRA Technical TeamRandall SchroederSenior Technicianand Seminar SpeakerSteve GarrettTechnical Advisor,Seminar Speaker,Service EngineerDavid SkoraSenior TechnicianPete HuscherTechnical AdvisorMike BrownTechnical AdvisorBill BraytonTechnical Advisor,Seminar SpeakerMike SouzaTechnical Advisor,Seminar SpeakerJon RodriguezTechnical Advisor 2009 ATRA. All Rights Reserved.

viIntroATRA StaffChief Executive Officer:GEARS Managing Editor:Dennis MaddenRodger BlandGEARS Magazine: Frank PasleyJeanette TroubEvents Manager:Event Services:Vanessa VelasquezKim ParisDirector of Membershipand IT Services:Membership Department:Kelly HilmerKim BrattinDeon OlmosJim SpitsenAccounting Manager:Accounting Department:Jody WintermuteRosa SmithValerie MitchellBookstore Manager:Shaun VelasquezATRA Bookstore: Ron Brattin 2009 ATRA. All Rights Reserved.

FordTable of ContentsFord43AWF-21BSolenoid Identification and Locations.44Pressure Regulator Valve Adjustment.45Upper Valve Body Valve Description.46Lower Valve Body Valve Description.47Middle Valve Body.48Upper Valve Body Top Side.50Upper Valve Body Check Valve Locations.51Lower Valve Body Check Valve Locations.52Accumulator Piston and Spring Location.536F50O/D Piston Return Snap Ring Removal.54Direct Clutch Return Snap Ring Removal.56Intermediate Piston Return Snap Ring Removal.58Reverse Piston Return Snap Ring Removal.59Specifications.604R70W/4R70/75E Interchange InformationAnti-Rattle Spring.62Center Support.63Forward Drum.64Intermediate Mechanical Diode Sprag.65Harness Connector Changes.66Stator Support.67Planetary.68Sun Shell and Forward Sun Gear.69Pump Body.72Ring Gear.73Output Speed Sensor.74Throttle Actuator Control.75TorqshiftLow/Reverse Planetary Gear Set Interchange.76ALL Ford’sErratic Speedometer Reading while Sitting Still.78 2009 ATRA. All Rights Reserved.

44 2009 ATRA. All Rights Reserved.Ford

45FordTogether, we can grow your transmission aftermarket businesswith full service warehouse locations, differentiated & expandedproducts, and efficient procurement methods.When you team with Parker for your aftermarket transmission repair and rebuild kits and components, you can expect services and products that will give you a competitive advantage. Our ToledoTransKit and Bryco brands include the highest quality components, including Parker manufacturedrubber seals. And that’s not all, we have expanded our product line in all of our warehouse locationsto include the components necessary for a complete rebuild. So team with Parker’s Seal AftermarketProducts Division for all of your transmission aftermarket kit needs.www.parker.com1 800 582 2760 2009 ATRA. All Rights Reserved.

46FordAWF-21BSolenoid Identification and LocationsThe Solenoid identifications and locations are important. If the Solenoids are installedinto the wrong location, shifting problems, codes, and ratio error will occur. SSA and SSB 11-15 ohmsSSC, SSD, SSE, TCC and PCA 5-7 ohmsCAUTION: There are “keepers” throughout this valve body. Pay close attention toyour disassembly process and use the following pages for reference. If a pin is lostduring your rebuild, a replacement can be made using a needle bearing.Pin Measurement size 0.932 x 0.118 2009 ATRA. All Rights Reserved.

47FordAWF-21BPressure Regulator Valve AdjustmentThis pressure regulator valve has a stepped sleeve. Always measure the distance fromthe tip of the sleeve to the valve body for proper installation.Always measure the distance fromthe tip of the sleeve to the valvebody for proper installation.0.158” 2009 ATRA. All Rights Reserved.

48FordAWF-21BUpper Valve Body Valve DescriptionUse the following illustrations for reference during your rebuild.1.2.3.4.5.6.7.8.9.10.11.12.13. 2009 ATRA. All Rights Reserved.TBDC2 Switch ValveTBDTBDTBDSecondary Regulator ValveB2 Control ValveTBDLock-Up Control ValveC3 Control ValveTBDServo Control ValvePCA Regulator Valve

49FordAWF-21BLower Valve Body Valve DescriptionUse the following illustrations for reference during your rebuild.1.2.3.4.5.6.7.8.9.TBDC1 Control ValveTBDSolenoid Regulator ValveTBDC1 AccumulatorC3 AccumulatorTorque Converter Regulator ValveSolenoid Regulator Valve 2009 ATRA. All Rights Reserved.

50FordAWF-21BMiddle Valve BodyCheck Valve and Spring Locations ‘Upper Side”Use the following illustrations for reference during your rebuild.White r”Light Blue SpringRed Spring 2009 ATRA. All Rights Reserved.

51FordAWF-21BMiddle Valve Body (continued)Check Valve and Spring Locations ‘Lower Side”Use the following illustrations for reference during your rebuild.Plain SpringPlain SpringThe accumulator check valves are installedwith the blue side facing down into the valvebody slot. 2009 ATRA. All Rights Reserved.

52FordAWF-21BUpper Valve Body Top SideThere are no manufacturer specifications for the spring tensioner depths. There are four(4) different valves with this type of layout. Always measure the depth of the tensionadjusters prior to disassembly.Always measure depthof adjusters prior todisassembly 2009 ATRA. All Rights Reserved.Servo Accumulator

53FordAWF-21BUpper Valve BodyCheck Valve LocationsUse the following illustration for check valves with spring and piston locations. Newcheck valves come in the rebuild kit and should be replaced with every rebuild.Red SpringWhite SpringRed SpringThe accumulator check valves are installedwith the blue side facing down into the valvebody slot. 2009 ATRA. All Rights Reserved.

54FordAWF-21BLower Valve BodyCheck Valve LocationsUse the following illustration for check valve with spring and piston locations. Newcheck valves come in the rebuild kit and should be replaced with every rebuild.White SpringWhite SpringRed SpringThe accumulatorcheck valves areinstalled with theblue side facingdown into the valvebody slot.Solenoid Feed Filters 2009 ATRA. All Rights Reserved.White Spring

55FordAWF-21BA ccumulator Piston and Spring LocationUse the following illustration for accumulator valve and spring locations. 2009 ATRA. All Rights Reserved.

56Ford6F50O/D Piston Return Snap Ring RemovalWe used parts from around the shop to take the place of the special tools needed todisassemble and reassemble the 6F50N. To remove the retaining snap ring from the ODclutch piston return spring assembly, you’ll need some parts from other transmissions: an A4LD/5R55E rear ring gear (for the low/reverse planet) a worn out OD clutch hub/shaft from a 4T60E a large deep socket a suitable press.Use a cutting wheel to cut large slots out of the 4th clutch hub/shaft. Place the ring gearon the clutch retainer and slide the 4th clutch hub down onto the ring gear. Use thedeep socket as an extension of the hub to be pressed down to remove the ring. 2009 ATRA. All Rights Reserved.

57Ford6F50O/D Piston Return Snap Ring Removal(continued)Deep Socket4T60E 4th clutchhub/shaftA4LD/5R55Erear ring gearPress down on the retainer just enough to access the snap ringAccess and removethe snap ring here 2009 ATRA. All Rights Reserved.

58Ford6F50Direct Clutch Return Snap Ring RemovalTo remove and install the direct clutch piston return spring without breaking the tab,use a: low/reverse piston from an AW50-42LE or a 4L30E reverse clutch piston a bar or 12 inch 3/8 extension.The 4L30E reverse piston will have to be modified with a cutting wheel to gain access tothe snap ring but it is the correct diameter to fit the direct clutch piston.4L30E Reverse Pistonbefore cut outs havebeen made 2009 ATRA. All Rights Reserved.AW50-42LE low/reversepiston-no modificationnecessary

59Ford6F50Direct Clutch Return Snap Ring Removal(continued)The drum is placed in the press and with the bar or extension across the piston to pushthe piston down evenly.CAUTION!! Only press the direct clutch cylinder down far enough to get thesnap ring out of its groove. Pressing the cylinder down too far can break the taband the cylinder.Access thesnap ringhereOnly press the direct clutch cylinder downfar enough to get the snap ring out. Pressingthe cylinder down too far can break the taband destroy the drum. 2009 ATRA. All Rights Reserved.

60Ford6F50Intermediate Piston Return Snap RingRemovalTo compress the intermediate clutch spring to remove and install the retaining snapring, use: an E40D/4R100 Sun Shell or RE5R05A Sun Shell (cut two slots opposite of eachother) a bar to use in the pressUse a cutting wheel or a torch, (much faster) to cut large notches out of the sun shell.These slots allow access to the snap ring. The slots should not be any wider than4 inches. Any larger and the return springs may get distorted when compressing thespring. 2009 ATRA. All Rights Reserved.

61Ford6F50Reverse Piston Return Snap Ring RemovalTo remove or install the reverse clutch return spring use: A pair of C clamp vice grips.Use the C clamp to compress the return spring. Use a screwdriver with a twisting motionto securely hold the snap ring in place. Move around the end cover in this way until theretaining ring is completely seated in the groove. 2009 ATRA. All Rights Reserved.

626F50Specifications 2009 ATRA. All Rights Reserved.Ford

Ford636F50Specifications (continued) 2009 ATRA. All Rights Reserved.

64Ford4R70W/4R70/75EInterchange InformationAnti-Rattle SpringFord has come up with a better designed anti rattle spring. The updated spring is a “V”shaped strip of spring steel that won’t eat into the case or center support. This springwill retrofit back all the way to the AOD transmission and is a great case saver for severely worn cases. The part number for the updated spring is 2L3Z-7F277-AA.Discard 2009 ATRA. All Rights Reserved.Updated SpringPart # 2L3Z-7F277-AA

65Ford4R70W/4R75EInterchange Information (continued)Center SupportTo make room for the turbine speed sensor, the 4R70E/75E center support has anextra notch cut out. If you install a 4R70W support in a 4R70E/75E case, the turbinespeed sensor will not install all the way into the case.If you are in a pinch, grinding a notch into the support to make room for the sensor willnot pose a problem. 2009 ATRA. All Rights Reserved.

66Ford4R70W/4R75EInterchange Information (continued)Forward Drum2004-on, forward drums have three clutch apply holes, 120º apart, verses the earlierversion having only one. This design change is cosmetic and will not affect forwardclutch apply if interchanged. The 4R70/75E drum will fit on all year models.Pre-2004 only has one applyhole 2009 ATRA. All Rights Reserved.2004-on, forward drums havethree clutch apply holes

67Ford4R70W/4R75EInterchange Information (continued)Intermediate Mechanical Diode SpragIn 2007, Ford introduced a new design mechanical diode. They increased the number ofratchet teeth in the diode which should increase holding strength. At the time of printingthis manual, there have been no reports of premature failure.The new diode has a snap ring that holds the element retainer in place instead of theearlier pressed design. Height dimensions have changed slightly where the snap ringrides on the reverse input/OD drum.The new design diode supersedes the previous design, and when used on any diode-styledrum, will increase the clearance between the inner race and the snap ring by about0.020", this is a normal clearance by design. An aftermarket-designed spiral snap ringshould be used in place of the stock snap ring to prevent snap ring failure. 2009 ATRA. All Rights Reserved.

68Ford4R70W/4R75EInterchange Information (continued)Harness Connector ChangesUse the diagrams to make sure you are using the correct connector for your application.The diagrams shown are the vehicle side of the harness. From 1993-1997, the transmission connector is white with soft wiring built into the connector.From 1998-on, the connector is black in color and uses the separate hard plasticharness. Solenoids will not interchange due to connection differences.NOTE: Installing the wrong wiring harness can create multiple codes and erraticshifts. 2009 ATRA. All Rights Reserved.

69Ford4R70W/4R75EInterchange Information (continued)Stator SupportThe stator supports are identical in hydraulic design but there is an important differencein the forward sealing ring lands. The 4R70E/75E uses a plastic ring that is muchthinner than the 4R70W cast iron design.The outer dimensions of the two rings are identical so as long as the correct rings areused, the stator supports can be interchanged.The other difference is the forward clutch feed hole. Ford changed the machining processfor the forward clutch apply hole and turned it into a slot instead of a round hole. This isstrictly cosmetic and will have no effect on forward clutch apply if interchanged. 2009 ATRA. All Rights Reserved.

70Ford4R70W/4R75EInterchange Information (continued)PlanetaryThe planetary gear set is the same ratio and dimensions between the two units. The onlydifference is how the rear cover is attached. The 4R70E/75E uses a welded design as theolder versions use rivets to connect the bottom cover to the top portion of the gear set.That area has never had a real issue and the change is due to an easier manufacturingprocess. Interchange between years will not pose a problem. 2009 ATRA. All Rights Reserved.

71Ford4R70W/4R75EInterchange Information (continued)Sun Shell and Forward Sun Gear2004 & up sun shells are designed with added strength by utilizing a two piece rivetedor a one piece design in the later applications. On both designs, the metal is thickeralong the chamfer at the base of the gear which will reduce cracking. Height dimensionsfrom the bottom of the sun gear to the area where the bearing rides has been reduced by.030” to make room for the thicker two piece bearing.The sun shell, bearing, and forward sun gear must be changed as a set if changing overto a 4R70W or the end play will be incorrect. Ford sells this complete service kit underpart # 4L3Z-7D234-AA.2.0550”2.0250” 2009 ATRA. All Rights Reserved.

72Ford4R70W/4R75EInterchange Information (continued)Sun Shell and Forward Sun Gear (continued)The sun shell, bearing, and forward sun gear must be changed as a set if changing overto a 4R70W or the end play will be incorrect. Ford sells this complete service kit underpart # 4L3Z-7D234-AA.Thicker two piece bearing.1.177”1.167”ID Groove 2009 ATRA. All Rights Reserved.

73Ford4R70W/4R75EInterchange Information (continued)Sun Shell and Forward Sun Gear (continued)The single most important change with the 4R70E/75E sun shell is something you cannot see with the naked eye, but will prevent the transmission from leaving your shop.That

low/reverse piston from an AW50-42LE or a 4L30E reverse clutch piston a bar or 12 inch 3/8 extension. The 4L30E reverse piston will have to be modified with a cutting wheel to gain access to the snap ring but it is the correct diameter to fit the direct clutch piston. 4L30E Reverse Piston before cut outs have been made

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