37automatictransmission studentguide …...lessonone workstationone 6....

AutomaticTransmission Service

37 Automatic Transmission

Student Guide

FCS21304REFFCS21304REFFCS21304REFFCS21304REF

Course Code: 37S13T1

Version 2

IMPORTANT SAFETY NOTICE

NOTE: Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design withoutnotice and without incurring any obligation.

REPAIR TECHNIQUESAppropriate service methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as thepersonal safety of the individual doing the work. This manual provides general directions for performing service with tested,effective techniques. Following them will help assure reliability.

There are numerous variations in procedure, techniques, tools and parts for servicing vehicles, as well as in the skill of theindividual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as toeach. Accordingly, anyone who departs from the instructions provided in this manual must first establish that they compromiseneither their personal safety nor the vehicle integrity by their choice of methods, tools or parts.

NOTE, NOTICE, CAUTION AND WARNINGAs you read through this manual, you may come across a NOTE, NOTICE, CAUTION or WARNING. Each one is there for aspecific purpose. A NOTE calls attention to unique, additional or essential information related to the subject procedure. ANOTICE identifies a hazard that could damage the vehicle or property. A CAUTION identifies a hazard that could result inminor personal injury to yourself or others. AWARNING identifies a hazard that could result in severe personal injury or deathto yourself or others. Some generalWARNINGS that you should follow when you work on a vehicle are listed below.

• ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

• KEEP SOLVENTS AWAY FROM IGNITION SOURCES. SOLVENTS MAY BE FLAMMABLE AND COULD IGNITE OREXPLODE IF NOT HANDLED CORRECTLY.

• USE SAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE VEHICLE.

• MAKE SURE THAT THE IGNITION SWITCH IS ALWAYS IN THE OFF POSITION, UNLESS OTHERWISE REQUIRED BYTHE PROCEDURE.

• SET THE PARKING BRAKE WHEN WORKING ON THE VEHICLE. IF YOU HAVE AN AUTOMATIC TRANSMISSION,SET IN PARK UNLESS INSTRUCTED OTHERWISE FOR A SPECIFIC OPERATION. IF YOU HAVE A MANUALTRANSMISSION, IT SHOULD BE IN REVERSE (ENGINE OFF) OR NEUTRAL (ENGINE ON) UNLESS INSTRUCTEDOTHERWISE FOR A SPECIFIC OPERATION. PLACE WOOD BLOCKS (4" X 4" OR LARGER) OR WHEEL CHOCKSAGAINST THE FRONT AND REAR SURFACES OF THE TIRES TO HELP PREVENT THE VEHICLE FROM MOVING.

• OPERATE THE ENGINE ONLY IN A WELLVENTILATED AREA TO AVOID THE DANGER OF CARBON MONOXIDEPOISONING.

• KEEP YOURSELF AND YOUR CLOTHING AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING,ESPECIALLY THE DRIVE BELTS.

• TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE RADIATOR, EXHAUSTMANIFOLD, TAIL PIPE, THREEWAY CATALYTIC CONVERTER AND MUFFLER.

• DO NOT SMOKE WHILE WORKING ON A VEHICLE.

• TO AVOID INJURY, ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND LOOSE CLOTHINGBEFORE BEGINNING TO WORK ON A VEHICLE.

• WHEN IT IS NECESSARY TO WORK UNDER THE HOOD, KEEP HANDS AND OTHER OBJECTS CLEAR OF THECOOLING FAN BLADES!

TOOLSCommercially available hand tools and equipment are used along with Essential Special Service Tools (ESST) and Rotundaequipment. Power tools have become the acceptable industry standard and are used for disassembly only where applicable,unless specified otherwise in the Workshop Manual. The only exception to this policy is installing wheels in conjunctionwith the use of torque sticks, when possible.

Copyright © 2013 Ford Motor Company Produced and Coordinated byTechnical Service Support OperationsFord Customer Service Division

Version 2

INTRODUCTION

INTRODUCTION

Automatic Transmission Service Intro 1 Version 2

INTRODUCTION

Course Description

This course is designed to reinforce information presented in the three prerequisite webbased courses and providestudents with handson activities to acquire and refine skills. This course will allow you to apply this information tospecific components and systems. Emphasis will be placed on handson activity, providing you the skills necessaryto inspect and repair current Ford automatic transmissions.

Worksheets

Course RequirementsEach technician attending this course is required to pass a combination of handson and written evaluations. Theseare administered after all lectures, demonstrations and/or practice sessions have been completed.

• The handson evaluation is a pass/fail type. It is conducted with exercises in automatic transmission assembly,and covers selected measurements.

To pass the course, you must demonstrate 100% mastery of the skills covered in the HandsOn PostTest exercisesAND you must correctly answer at least 80% of the Written PostTest and component inspection questions.

Course ObjectivesUpon successful completion of this course, you will be able to:

• disassemble a Rear Wheel Drive (RWD) automatic transmission and inspect various components.

• disassemble a Front Wheel Drive (FWD) automatic transmission and inspect various components.

• perform various automatic transmission critical measurements and determine next steps.

• assemble a RWD automatic transmission to proper working condition.

• assemble a FWD automatic transmission to proper working condition.


INTRODUCTION

Course Agenda

LESSON ONE:

• Introductions and Prerequisite Review

• Workstations Explorer (6R60/75)

LESSON TWO:

• Workstation Review

• Workstations Edge (6F50)

LESSON THREE:

• Workstation Review

• Workstations Transit Connect (4F27E), ESeries (4R70W), Fusion (6F35), valve body operation and solenoidreplacement (6F35 and 6F50)


INTRODUCTION

NOTES


LESSON ONE PREREQUISITE REVIEW

LESSON ONE

Automatic Transmission Service 1 1 Version 2


NOTES



PREREQUISITEREVIEW



PREREQUISITE REVIEW

DIRECTIONS: Answer the following questions on automatic transmissions. Questions may be related to theory,operation, and service. If you do not know the answer, move on to the next question. These will be reviewed in class.

1. Describe the four ways a simple planetary can produce output. Give an example of what is held in each outputstate.

____________________________________________________________________________________________________________________________________________

2. What is the difference between “simple” and “Ravigneaux” style planetaries?

____________________________________________________________________________________________________________________________________________

3. What do bands and oneway clutches have in common?

____________________________________________________________________________________________________________________________________________

4. Bearings, bushings, and thrust washers are critical components in any transmission. Describe why.

____________________________________________________________________________________________________________________________________________

5. Transmission fluid condition is critical for proper transmission operation. Describe two types of fluidcontamination.

____________________________________________________________________________________________________________________________________________



6. Transmission fluid level is critical for proper transmission operation. What can happen with improper fluid level?

____________________________________________________________________________________________________________________________________________

7. How are transmission coolers and lines serviced when a transmission is replaced or rebuilt?

____________________________________________________________________________________________________________________________________________

8. Fluid pumps are a critical component in any automatic transmission. Why?

____________________________________________________________________________________________________________________________________________

9. During disassembly how would you check for a sticking valve?

____________________________________________________________________________________________________________________________________________



NOTES



LESSON ONE WORKSTATION

LESSON ONEWORKSTATION


LESSON ONE WORKSTATION

NOTES

LESSON ONE WORKSTATION ONE

WORKSTATION ONEExplorer (6R60/75)

SUMMARY: For this activity, disassemble an Explorer (6R60/75) transmission down to its major subassembliesand perform inspections required by the Workshop Manual. You will be given a set of replacement clutch pistonsafter disassembly. Install the replacement clutch pistons as part of the assembly of subassemblies.

• DISASSEMBLY – Students will disassemble an Explorer (6R60/75) transmission.

• SUBASSEMBLIES – Students will disassemble, inspect and assemble select Explorer (6R60/75) transmissionsubassemblies.

• ASSEMBLY – Students will inspect, adjust and assemble an Explorer (6R60/75) transmission.

DIRECTIONS: Complete Workstation 1 at the bench workstation, using the Explorer (6R60/75) transmission,available hand tools, special service tools, and the Workshop Manual.

• Disassembly

• Follow the 2008 Explorer Workshop Manual, Section 30701B, to disassemble the Explorer (6R60/75)transmission to its major subassemblies. (Use the appropriate model year and vehicle Workshop Manualfor the transmission in class.)

• Disassemble the forward/overdrive clutch assembly (Refer to Subassemblies in the Workshop Manual).

• As you perform the disassembly procedures, answer the following questions related to the key steps:



1. Inspect the front planetary, the Ravigneaux planet carrier, low/ reverse clutch, parking pawl, and the case fromthe disassembled transmission. Circle the areas on the following images of each component that must beinspected.

2. If you had a damaged tooth on the long pinion gear of the Ravigneaux gearset, what else would requireinspection?

____________________________________________________________________________________________________________________________________________

NOTE: Use the components on the bench to answer the following questions:

3. The intermediate clutch holds the # 2 sun gear stationary when applied in M2 (Manual 2nd), 2ndand 6th gears.

4. The direct clutch transfers torque from the front planet carrier to the # 2 sun gear whenapplied in Reverse, M3 (Manual 3rd), 3rd and 5th gears.

5. The forward clutch transfers torque from the front planet carrier to the # 3 sun gear whenapplied in 1st, 2nd, 3rd, M1, M2, M3, ( Manual 1st, 2nd, 3rd), and 4th gears.



6. The overdrive clutch transfers torque from the turbine shaft to the rear planet carrier whenapplied in 4th, 5th and 6th gears.

7. The low/reverse clutch holds the rear planet carrier stationary when applied in reverse and 1st gear.

• SUMMARY: For this activity, disassemble, inspect and assemble each of the following subassemblies:front pump, forward clutch, overdrive clutch, direct clutch, intermediate clutch, low/reverse clutch, andMechatronics® unit from an Explorer (6R60/75) transmission.

Directions: Install the instructor supplied replacement parts before assembly of the subassemblies.

Subassemblies

• Follow the 2008 Explorer Workshop Manual, Section 30701B, to disassemble and assemble the Explorer(6R60/75) transmission subassemblies (use the appropriate model year Workshop Manual for thetransmission in class).

• As you perform the disassembly and assembly procedures, answer the following questions related to thekey steps.

8. Inspect the center support, overdrive hub, and front pump from the disassembled transmission. Circle the areason the following images of each component that must be inspected.



9. Answer the following questions:

What is the intermediate clutch clearance? 1.17 mmWhat is the intermediate clutch specification? 0.48 — 0.89 mmWhat adjustment is needed? Thicker snap ringWhat is the thickness of the existing selective part? 2.29 mmWhat is the thickness of the required selective part? 2.76 mm


What is the direct clutch clearance? 1.37 mmWhat is the direct clutch specification? 0.28 — 1.09 mmWhat adjustment is needed? Thicker snap ringWhat is the thickness of the existing selective part? 2.95 mmWhat is the thickness of the required selective part? 3.61 mm


What is the forward clutch clearance? 0.31 mmWhat is the forward clutch specification? 0.48 — 0.89 mmWhat adjustment is needed? Thinner snap ringWhat is the thickness of the existing selective part? 4.14 mmWhat is the thickness of the required selective part? 3.76 mm


What is the overdrive clutch clearance? 0.74 mmWhat is the overdrive clutch specification? 0.28 — 0.69 mmWhat adjustment is needed? Thicker snap ringWhat is the thickness of the existing selective part? 2.36 mmWhat is the thickness of the required selective part? 2.62 mm

13. Why is an alignment mark made between the forward clutch balance piston and the forward clutch cylinderbefore removing the piston?

____________________________________________________________________________________________________________________________________________



14. In which direction is the step facing on the direct clutch return spring retaining ring?

____________________________________________________________________________________________________________________________________________

15. Which plates in the center support intermediate clutch assembly have a wave design?

____________________________________________________________________________________________________________________________________________

16. When installing the sealing rings on an Explorer (6R60/75) front pump, how do you orient the ring gaps?

____________________________________________________________________________________________________________________________________________

17. What is the purpose of the check ball at the top of the center support Low/Reverse piston bore?

____________________________________________________________________________________________________________________________________________

18. Why are there three seals on the low/reverse clutch piston?

____________________________________________________________________________________________________________________________________________



19. Identify the locations of the check balls and shuttle balls in the image below.

20. Answer the following questions about the low reverse clutch:

What is measurement A? 33.15 mmWhat is measurement B? 21.39 mmWhat is measurement C? 10.21 mmWhat is the low/reverse clutch clearance? 1.55 mmWhat is the low/reverse clutch specification? 0.79 — 1.40 mmWhat adjustment is needed? Thicker steel plateWhat is the thickness of the existing selective part? 5.08 mmWhat is the thickness of the required selective part? 5.56 mm

• SUMMARY: For this activity, assemble an Explorer (6R60/75) transmission, performing measurements andinspections required by the Workshop Manual.

Assembly

• Follow the 2008 Explorer Workshop Manual, Section 30701B, to assemble the Explorer (6R60/75)transmission and perform any necessary inspections and measurements (use the appropriate model yearWorkshop Manual for the transmission you have).




What is the rear end play? 0.12 mmWhat is the rear end play specification? 0.15 — 0.33 mmWhat adjustment is needed? Thinner shimWhat is the thickness of the existing selective part? 1.52 mmWhat is the thickness of the required selective part? 1.42 mm


What is the front end play? 0.36 mmWhat is the front end play specification? 0.20 — 0.36 mmWhat adjustment is needed? No adjustment necessaryWhat is the thickness of the existing selective part? 2.39 mmWhat is the thickness of the required selective part? 2.39 mm

23. Is the pan gasket reusable?

____________________________________________________________________________________________________________________________________________



NOTES


LESSON TWO

LESSON TWO


LESSON TWO

NOTES



LESSON TWO WORKSTATION

LESSON TWOWORKSTATION


LESSON TWO WORKSTATION

NOTES

LESSON TWO WORKSTATION ONE

WORKSTATION ONEEDGE (6F50)

SUMMARY: For this activity, disassemble an Edge (6F50) transmission down to its major subassemblies andperform inspections required by the Workshop Manual. You will be given a set of replacement clutch pistons afterdisassembly. Install the replacement clutch pistons as part of the reassembly of the subassemblies.

Students will use the Workshop Manual, required special tools and an Edge (6F50) transmission and answerrelated questions during:

• DISASSEMBLY – Students will disassemble an Edge (6F50) transmission.

• SUBASSEMBLIES – Students will disassemble, inspect and assemble select the Edge (6F50) transmissionsubassemblies.

• Assembly Students will assemble an Edge transmission

DIRECTIONS: Complete Workstation 2 at the bench workstation, using the Edge (6F50) transmission, availablehand tools, special service tools, and the Workshop Manual.

Disassembly

• Follow the 2010 Edge Workshop Manual, Section 30701, to disassemble the Edge (6F50) transmission toits major subassemblies.

• As you perform the disassembly procedures, answer the following questions related to the key steps.

1. Inspect the front, center and rear planetaries. Circle the areas on the graphics of each component to inspect.



NOTE: Use the components on the bench to answer questions 2 6.

2. The forward clutch holds the front sun gear stationary when applied in 1st, 2nd, 3rd, and 4th gears.

3. The low/reverse clutch holds the rear planet carrier/center ring gear stationary when applied inReverse, 1st gear and Low only.

4. The intermediate clutch holds the rear sun gear stationary when applied in 2nd and 6th gears.

5. The direct clutch transfers torque from the turbine shaft to the rear sun gear when appliedin 3rd, 5th, and reverse gears.

6. The overdrive clutch transfers torque from the turbine shaft tothe rear planet carrier / center ring gear when applied in 4th, 5th, and 6thgears.



7. What is the purpose of the plastic reservoir near the top of the case? Why does it have a check ball? Hint: Theanswer is NOT in the Workshop Manual.

____________________________________________________________________________________________________________________________________________

• DIRECTIONS: For this activity, disassemble and assemble the pump and filter assembly, pump chain andsprocket, main control assembly, solenoid body assembly, planetary gear assembly, low oneway clutch,overdrive/direct clutch assembly, and cover assembly on a Edge (6F50) transmission and perform inspectionsrequired by the Workshop Manual.

Subassemblies

• Follow the Edge Workshop Manual, Section 30701, to disassemble and assemble the Edge (6F50)transmission subassemblies.

• As you perform the disassembly and assembly procedures, answer the following questions related tokey steps.



8. Main Control Disassembly: Identify the check ball locations and identify which locations are not used.Circlethe areas below where check balls go, and place an X where they do not.

9. What parts are serviceable on the solenoid body?

____________________________________________________________________________________________________________________________________________

10. What additional procedure must be performed if the solenoid body is replaced?

____________________________________________________________________________________________________________________________________________

11. What inspection procedure is performed to determine if the fluid pump is reusable?

____________________________________________________________________________________________________________________________________________



12. If the fluid pump is reusable, what service procedure is done on the fluid pump?

____________________________________________________________________________________________________________________________________________

13. What seals must be serviced on the stator support?

____________________________________________________________________________________________________________________________________________

14. If the forward clutch pressure plate is damaged, what component must also be replaced?

____________________________________________________________________________________________________________________________________________

15. How do you align the low/reverse clutch piston bleed hole during assembly?

____________________________________________________________________________________________________________________________________________

16. Should the low oneway clutch be disassembled for cleaning and inspection?

____________________________________________________________________________________________________________________________________________

17. How far do you compress the direct clutch piston return spring?

____________________________________________________________________________________________________________________________________________

18. The overdrive clutch has a balance piston to maintain full release of the clutch. What is used to allow fullrelease of the direct clutch?

____________________________________________________________________________________________________________________________________________

19. What is used to lift the pressure plate when measuring overdrive and direct clutch pack clearance?

____________________________________________________________________________________________________________________________________________




What is the direct clutch clearance? 1.25 mmWhat is the direct clutch specification? 0.99-2.34 mmWhat adjustment is needed? If out of spec, replace clutchWhat is the thickness of the existing selective part? No adjustmentWhat is the thickness of the required selective part? No adjustment


What is the overdrive clutch clearance? 1.96 mmWhat is the overdrive clutch specification? 1.14-2.29 mmWhat adjustment is needed? If out of spec, replace clutchWhat is the thickness of the existing selective part? No adjustmentWhat is the thickness of the required selective part? No adjustment

• DIRECTIONS: For this activity, assemble an Edge (6F50) transmission, performing measurements andinspections required by the Workshop Manual.

Assembly

• Follow the 2010 Edge Workshop Manual, Section 30701, to assemble the Edge (6F50) transmission andperform inspections and measurements.

• If adjustments are required, identify the correct size selectfit part that is needed.


What is the final drive preload measurement #1? 0.81 mmWhat is the final drive preload measurement #2? 0.76 mmWhat is the average of the final drive preloadmeasurements?

0.79 mm

What is the thickness of the existing selective part? 0.74 mmWhat adjustment is needed? 0.05 mm thicker shimWhat is the thickness of the required selective part? 0.79 mmWhat is the part number of the correct selective part? 7T4Z–4067–K




What is the transfer shaft preload measurement #1? 0.86 mmWhat is the transfer shaft preload measurement #2? 0.76 mmWhat is the average of the transfer shaft preloadmeasurements?

0.81 mm

What is the thickness of the existing selective part? 0.76 mmWhat adjustment is needed? 0.05 mm thicker shimWhat is the thickness of the required selective part? 0.81 mmWhat is the part number of the correct selective part? 7T4Z–7H367–L

24. What would happen if the gap for the low oneway retaining snap ring was not positioned correctly in the case?

____________________________________________________________________________________________________________________________________________



NOTES


LESSON THREE

LESSON THREE


LESSON THREE

NOTES



LESSON THREE WORKSTATIONS

LESSON THREEWORKSTATIONS


LESSON THREE WORKSTATIONS

NOTES

LESSON THREE WORKSTATION ONE

WORKSTATION ONETransit Connect (4F27E)

SUMMARY: For this activity you will perform the following assembly tasks: Shim measurements for differentialand transfer shaft bearings.

DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to disassemble, inspect, measureand reassemble the transmission from a Transit Connect (4F27E) and answer related questions on the worksheet. Asthe Shop Aid directs you, answer questions on your worksheets.

• Assembly

1. What is the differential bearing measurement? 0.56 mm What is the thickness of the selectivepart? 0.74 mm What is the part number of the required selective part? Diff = XS4P-7F119–FB

2. What is the transfer bearing clearance? 0.71 mm What is the thickness of theselective part? 0.84 mm What is the part number of the required selectivepart? Transfer= XS4P-7H367–HB

• SUMMARY: For this activity you will perform the following assembly tasks: Fluid pump inspection and bandadjustment, installation and reverse clutch measurement.

3. Perform the intermediate/overdrive band adjustment procedure. What is the required selective component?

____________________________________________________________________________________________________________________________________________

4. What is important about pump fluid gear installation orientation?

____________________________________________________________________________________________________________________________________________


What is the reverse clutch clearance? 1.19 mm

What is the reverse clutch specification? 0.99 mm – 1.30 mmWhat adjustment is needed? NoneWhat is the thickness of the existing selective part? 1.42 mmWhat is the thickness of the required selective part? 1.42 mm


LESSON THREE WORKSTATION ONE

NOTES


LESSON THREE WORKSTATION TWO

WORKSTATION TWOESeries (4R70W)

SUMMARY: For this activity you will perform the following assembly tasks: Reverse Clutch measurement andadjustment, end play, low/reverse band adjustment and servo.

DIRECTIONS: Students will use the Shop Aid Booklet and required special tools to perform selected proceduresan ESeries (4R70W) transmission and answer related questions on the worksheet. As the Shop Aid directs you,answer questions on your worksheets.

• Assembly

Reverse Clutch


What is the reverse clutch clearance? 3.12 mmWhat is the reverse clutch specification? 1.27 mm – 1.93 mmWhat adjustment is needed? Thicker snap ringWhat is the thickness of the required selective part? 3.20 mmIs the selective part available in that thickness ? No


What is the reverse clutch clearance? 1.63 mmWhat is the reverse clutch specification? 1.27 mm – 1.93 mmWhat adjustment is needed? No adjustment is requiredWhat is the thickness of the required selective part? 1.93 mm

• Front End Play


What is the measurement for the No.1 thrust washer? 38.48 mmWhat is the required thickness of the No.1 thrustwasher?

1.72 mm - 1.83 mm

What is the color of the correct selective part? Yellow

• Low/reverse clutch


LESSON THREE WORKSTATION TWO


What is the reverse band servo travel measurement? 7.24 mmWhat is the reverse band servo travel specification? 2.84 mm – 6.02 mmWhat adjustment is needed? Longer rodWhich servo actuating rod is installed in thetransmission?

One groove

What is the number of grooves on the correct selectivepart?

Three grooves = 4.52 mm / Twogrooves = 5.89 mm


LESSON THREE WORKSTATION THREE

WORKSTATION THREEFusion (6F35)

SUMMARY: For this activity you will answer the following questions about the Fusion 6F35 power flow. Perform6F35 disassembly on the workbench following the shop aid booklet.

DIRECTIONS: Students select the letter of the component that correctly completes each power flow statement.List all choices that apply.

A. Front sun gear B. Front carrier C. Front ring gear

D. Center sun gear E. Center carrier F. Center ring gear

G. Rear sun gear H. Rear carrier

J. Turbine shaft K. Output shaft

I. Rear ring gear

1. The forward clutch holds the A. Front Sun Gear stationary when applied in 1st, 2nd, 3rd and 4th gears.

2. The low/reverse clutch holds the F. Center Ring Gear + H. Rear Carrier stationary when applied in1st and Reverse gears.

3. The low oneway clutch holds the F. Center Ring Gear + H. Rear Carrier stationary underacceleration in 1st gear.

4. The intermediate clutch holds the G. Rear Sun Gear stationary when applied in 2nd and 6th gears.

5. The direct clutch transfers torque from the J. Turbine Shaft to the G. Rear Sun Gear whenapplied in 3rd, 5th and Reverse gears.

6. The overdrive clutch transfers torque from the J. Turbine Shaft tothe F. Center Ring Gear + H. Rear Carrier when applied in 4th, 5th, and 6th gears.


LESSON THREE WORKSTATION THREE

NOTES


LESSON THREE WORKSTATION FOUR

WORKSTATION FOUR PART ONEValve Removal and Inspection (6F35)

SUMMARY: In this activity disassemble the 6F35 valve body assembly on the bench. Perform any inspectionsrequired by the Workshop Manual. Discuss the valve body with your instructor.

DIRECTIONS: In Part 1 of this workstation, you will learn how valve bodies work. You will remove the mainpressure regulator valve, forward clutch regulator and latch valves and the clutch control bypass valve.

• Disassemble the valve body, when finished call the instructor over.

• Once the instructor has inspected your work, reassemble the valve body.



WORKSTATION FOUR PART TWOSolenoid Replacement (6F35)

SUMMARY: In this activity remove and inspect solenoids on the bench. Note the numbers on the solenoids andanswer the following questions.

DIRECTIONS: In the part 2 of this workstation, you will remove the shift solenoids and identify the part numberof the correct replacement solenoids.

1. Enter the part number of the correct replacement solenoid:

1. SSA: 9L8Z 7G1362. SSB: 9L8Z 7G383

3. SSC: 9L8Z 7G136

4. SSD: 9L8Z 7G383

5. SSE: 9L8Z 7G484 A

6. TCC: 9L8Z 7G136

7. LPC: 9L8Z 7G383

8. The 13 digit solenoid body strategy is:

9. The 7 digit solenoid body ID is:



WORKSTATION FOUR PART THREELincoln MKS (6F50)

SUMMARY: For this activity diagnose the vehicle concern.

DIRECTIONS: In part 3 of this workstation, you will diagnose a shift concern on a 6F50. Complete WorkstationFour Part 3 on the MKS. Use the supplied OASIS report to aid in your diagnosis.

Repair Order

Year 2014 Model Lincoln MKS

Engine 3.5L GTDI Trans 6F50/6F55 Other

Customer ConcernSometimes the vehicle shifts hard, sometimes transmission seems to slip during shifting. Veryerratic.

Vehicle History/ OASIS results/ TSBs. REPAIR HISTORY2/10/14 Harper Ford Inc. Control module transmission (TCM) replacement. Part number: 7T4Z 7Z369 E Part description:CONTROL MOD TRANS (TCM) Labor Op: 7396A1 Condition Description: DOES NOT OPERATE PROPERLY. SPECIAL SERVICE MESSAGESNo related SSMs

. TECHNICAL SERVICE BULLETINSNo related TSBs

IMPORTANT NOTES:

—

6F50

1. The 13 digit solenoid body strategy stored in the PCMis: Answers will vary depending on vehicle used



2. The 7 digit solenoid body ID stored in the PCM is: Answers will vary depending on vehicle used

3. The transmission solenoid body service tag on the transmission is which type?

A. Original

B. Replacement

4. Based on the OASIS report for this vehicle, what is your next step?

A. Return the vehicle to the customer

B. Reprogram the PCM with the solenoid ID and strategy from the transmission tag

C. Remove the main control cover and retrieve the solenoid ID and strategy from the solenoid body

D. None of the above


APPENDIX

STUDENT GUIDEAPPENDIX

Automatic Transmission Service Appendix 1 Version 2

APPENDIX

NOTES


APPENDIX

TorqShift Band and Clutch Application Chart

Gear O/DClutch

CoastClutch

O/DOnewayClutch

IntermediateClutch

Direct Clutch FowardClutch

Low/ReverseClutch

Low/RearOnewayClutch

O/D 1st D D H

O/D 2nd H OR D H

O/D 3rd D H D OR

O/D 4th a H OR H D OR

O/D 5th D D OR

O/D 6th H OR D D OR

M 3rd A D H D OR

M 2nd H D H H

M 1st A D D H H

Reverse A D D HPlanetaryMember

HoldsO/D SunGear

DrivesO/D SunGear

DrivesO/D SunGear

HoldsCommonSun Gear

Drives CommonSun Gear

DrivesForwardRing Gear

HoldsLow/RevCarrier

HoldsLow/RevCarrier

a 4th gear only, used when cold shift strategy is in effect at 0° F to 30°F

D = Drives A = Applied H = Holds OR = Overrunning


APPENDIX

6F35/6F50/6F55 Band and Clutch Application Chart

Gear ForwardClutch

DirectClutch

Intermediate Clutch

OverdriveClutch

LowReverseClutch

OnewayClutch

TurbineShaft

1st Gear D H H H D

2nd Gear D H H O/R D

3rd Gear D H D O/R D

4th Gear D H D O/R D

5th Gear D D D O/R D

6th Gear D H D O/R D

Reverse D H O/R D

PlanetaryMember

Holds FrontSun Gear

Drives RearSun Gear

Holds RearSun Gear

DrivesCenter RingGear and

Rear Carrier

Holds RearCarrier andCenter Ring

Gear

Holds RearCarrier andCenter Ring

Gear

DrivesCenter Sun

Gear

D = Drives H = Holds O/R = Overrunning

6R60/6R75 Band and Clutch Application Chart

Gear Forward (A)Clutch

Direct (B) Clutch Intermediate (C)Clutch

Low/ Reverse(D) Clutch

Overdrive (E)Clutch

Park H

Reverse D H

Neutral H

1st Gear Manual D H

2ndGearManual D H

3rd Gear Manual D D

1st Gear D D H

2nd Gear D D H

3rd Gear D D D

4th Gear D D D

5th Gear D D D

6th Gear H D

PlanetaryMember

Drives Sun 3 Drives Sun 2 Holds Sun 2 Holds RearPlanet Carrier

Drives RearPlanet Carrier

D = Drives H = Holds


APPENDIX

6R80/6R140 Band and Clutch Application Chart

Gear Forward (A)Clutch

Direct (B)Clutch

Intermediate (C)Clutch

Low/ Reverse(D) Clutch

Overdrive (E)Clutch

One way Clutch

Park H

Reverse D H

Neutral H

1st Gear Manual D H

2nd GearManual

D H

3rd Gear Manual D D

1st Gear D D H H

2nd Gear D D H

3rd Gear D D D

4th Gear D D D

5th Gear D D D

6th Gear H D

PlanetaryMember

Drives Sun 3 DrivesSun 2

Holds Sun2

Holds RearPlanet Carrier

Drives RearPlanet Carrier

Holds RearPlanet Carrier

4R70W/AODE/AOD Band and Clutch Application Chart

Gear Intermediate Clutch

Intermediate OWC

OverdriveBand

ReverseClutch

ForwardClutch

PlanetaryOWC

Low andReverseBand

DirectClutch

O/D 1st D H

O/D 2nd A H D OR

O/D 3rd Aa OR D OR D

O/D 4th A H OR D

M 2nd A H H D OR

M 1st D H H

Reverse D H

PlanetaryMember

Holdsouter raceof IntermediateOWC

HoldsReverseSun gear

HoldsReverseSun gear

DrivesReverseSun gear

DrivesForwardSun gear

HoldsPlanetaryCarrier

HoldsPlanetaryCarrier

DrivesPlanetaryCarrier

a Applied, but has no effect on power flow due to overrunning intermediate one way clutch.



APPENDIX

5R55E Band and Clutch Application Chart

Gear FrontBand

CoastClutch

FrontOneWayClutch

Intermediate Band

DirectClutch

ForwardClutch

Low/ReverseBand

Low/RearOnewayClutch

O/D 1st D D H

O/D 2nd H OR D H

O/D 3rd D H D OR

O/D 4th A D D D OR

O/D 5th H OR D D OR

M 2nd/3rdgear

A D H D OR

M 1st A D D H H

Reverse A D D H

PlanetaryMember

HoldsFront SunGear

DrivesFront SunGear

DrivesCenterShaft

HoldsCommonSun Gear

DrivesCommonSun Gear

DrivesForwardRing Gear

HoldsLow/RevCarrier

HoldsLow/RevCarrier


4F27E Band/Clutch Application Chart

Gear ForwardClutch

Direct Clutch ReverseClutch

Intermediate/OverdriveBand

Low ReverseClutch

Low OnewayClutch

R D H

N

4th D H O/R

3rd D D O/R

2nd D H O/R

1st D H

3rd (Manual) D D O/R

2nd (Manual) D H O/R

1st (Manual) D H H

PlanetaryMember

Drives FrontSun

Drives RearCarrier andFront Ring

Drives RearSun

Holds RearSun

Holds FrontRing

Holds FrontRing



APPENDIX

First Gear


APPENDIX

NOTES


APPENDIX

Second Gear


APPENDIX

NOTES


APPENDIX

Third Gear


APPENDIX

NOTES


APPENDIX

Fourth Gear


APPENDIX

NOTES


APPENDIX

Fifth Gear


APPENDIX

NOTES


APPENDIX

Sixth Gear


APPENDIX

NOTES


APPENDIX

Reverse Gear


37automatictransmission studentguide …...lessonone workstationone 6....

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