August 2010

FOR THE TRANSMISSION REBUILDING INDUSTRY

AUGUST 2010

TM

The RE5R05A: A Deeper LookThe Aisin Warner 6-Speed to San AntonioQuattro and 4Motion: Volkswagen Group’s Answer to All-Wheel Drive

ATRA's Powertrain

Expo, San Antonio Convention

CenterSeptember 9-12, San Antonio, TX

1.

2.

4.

5.

6.

3.

JF010E Main Valve Body

JF010E Middle Valve Body

Automatic Drive • Bellows Falls, VT 05101-0440 USA • 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com©2010 Sonnax Industries, Inc.

PROBLEM SOLUTION Tool Required Part Number

• Chatter/Noise on acceleration 1. Solenoid Regulator Valve Kit 113741-01K

• Loss of ratio change

• Chain slippage & pulley fracture 2. Oversized Secondary Pulley Control Valve Kit F-113741-TL17 113741-17K*

• RPM surge/chatter on acceleration & VB-FIX 113741-19K*

• Jerking on coastdown/harsh engagement 3. Lockup Control Sleeve & Plunger Valve Kit 113741-11K

• High engine RPM due to no lockup

• Chatter on acceleration 4. Oversized Primary Pressure Regulator F-113741-TL9 113741-09K • High/Low line pressure Valve Kit & VB-FIX

• Chain slippage & pulley fracture 5. Oversized Secondary Regulator Valve Kit F-113741-TL13 113741-13K*

• RPM surge/chatter on acceleration & VB-FIX 113741-15K*

• Engine stalls on engagement

6. Oversized TCC Limit & Lube Valve Kit F-113741-TL4 113741-04K • Loss of lockup & VB-FIX

• Slippage 7. Pump Flow Control Valve Repair Kit F-113741-TL7C 113741-07K†

• Delayed engagement into forward & reverse & VB-FIX

9 Sonnax Kits for Jatco/Nissan CVT

*Part numbers 113741-17K & -15K are for JF010E only & part numbers 113741-19K & -13K are for JF011E only. †Part number 113741-07K fits the JF010E pump only.

JF010E PumpJF010E Pump

7.

JF011E Valve Body

1.

2.3.

4.5.

6.

SPECIAL INTEREST & TECHNICAL 6 Fun with transmissions: the aisin warner 6-speed

to san antonio by Bill Brayton

10 Keep those tranny’s rolling: Quattro and 4motion:

Volkswagen group’s answer to all-wheel Drive

— by Pete Huscher

16 the re5r05a: a Deeper look by Mike Souza

20 it’s time to shift gears; the magna powertrain

transfer Case by Steve Garrett

22 a Closer look at Vw’s 09g by Dave Skora

28 Day one: safety training

by State Compensation Insurance Fund

30 DoCtor DoCtor: understanding the Dodge Family

of CVt units by Randall Schroeder

32 what's worKing: now we have the proof! by Dennis Madden

36 street smart: u660e: Diagnosing the toyota 6-speed

by Mike Brown

42 transtar industries inc. announces winners of

their “Best ink” promotion

44 atra s powertrain eXpo 2010, San Antonio Convention Center September 9-12, San Antonio, TX

48 memBership matters: atra's local search –

Bringing real performance by Dennis Madden

51 atra news: ATRA Groups Now Interactive Online

DEPARTMENTS 2 From the presiDent: expo 2010;

san antonio, texas by Jim Rodd

4 From the teChniCal DireCtor:

the Cream of the Crop

by Lance Wiggins

53 powertrain industry news

57 shoppers and Classified

64 list of advertisers

The views expressed in this publication should not necessarily be interpreted as the official policy of the Automatic Transmission Rebuilders Association (ATRA). Publication of product information or any advertising does not imply recommenda-tion by ATRA.

GEARS™, a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030, is published for the betterment of the transmission industry and is distributed nine times per year. No part of this issue may be reproduced without prior written permission of the publisher. GEARS is distributed to members of the transmis-sion industry in the United States, Canada, ATRA Members in Mexico & Europe, and related automotive industry firms and individually. Send changes of address to GEARS in care of ATRA. Subscriptions are available by contacting GEARS in care of ATRA.

Advertisers and advertising agencies assume full liability for all content of adver-tisements printed and also assume full responsibility for any claims arising there-from against the publisher. The publisher reserves the unqualified right to reject any advertising copy as it deems appropriate, with or without cause.

GEARS is designed to provide accurate and authoritative information in regard to the subject matter covered. It is distributed with the understanding the publisher is not engaged in rendering legal, accounting or other professional service. If legal advice or other expert assistance, is required, the services of a competent profes-sional person should be sought— from a Declaration of Principles jointly adopted by a Committee of the American Bar Association and Committee of Publishers.

GEARS also welcomes articles submitted by members of the industry. GEARS considers all articles for publication that contribute positively to the welfare of the transmission industry, and reserves the right to edit all articles it publishes. If you would like to submit an article to GEARS, include background information about the author and a telephone number where he/she may be reached. If you want submissions returned, enclose a self-addressed, stamped envelope.

Chief Executive Officer Dennis Madden Managing Editor Rodger Bland Technical Director Lance Wiggins Advertising Frank Pasley Senior Designer Jeanette Troub Circulation Richard Hurley

Contributing Editors: Steve Bodofsky State Compensation Insurance Fund

ATRA Technical Staff: Bill Brayton Mike Brown Steve Garrett Pete Huscher Randall Schroeder Mike Souza

Director of Membership & IT Svc Kelly Hilmer Seminars & Convention Manager Vanessa Velasquez Bookstore Manager Shaun Velasquez

publications mail agreement no. 40031403return undeliverable Canadian addresses to:

station a, po Box 54, windsor, on n9a 6J5email: [email protected]

issue #150 printed in u.s.a. Copyright atra 2010

Editorial and Business Offices2400 Latigo Avenue, Oxnard CA 93030Phone (805) 604-2000Fax (805) 604-2006www.gearsmagazine.comwww.atra.com

TABLE OF CONTENTS

Quattro and 4MotionPage 10

FOR THE TRANSMISSION REBUILDING INDUSTRY

The Aisin Warner 6-Speed Page 6

The RE5R05A: A Deeper LookPage 16

GEARSAUGUST 2010

PHONE (805) 604-2000 FAX (805) 604-2006

A. The Alamo �B. Arneson River Theater �(P)

P. The Aztec on the RiverTM

C. Blue Star Arts Complex �(P)

D. Buckhorn Saloon & Museum �+

E. Casa Navarro State Historical Park

F. Children’s Museum �+

G. HemisFair Park �� Shops & Deli � Children’s Playground

H. Institute of Texan Cultures �+

I. Instituto Cultural Mexicano �+

J. King William Historic District �(P)

K. La Villita �+

L. Market Square/El Mercado �+

C. Missions Historic Park �M. Museums �+

N. Navarro House �O. San Fernando Cathedral �(P)

Q. Southwest School of Artand Craft �+

R. Spanish Governor’s Palace �S. Steves HomesteadT. St. Paul Square �(P)

U. The Texas Adventure �+

V. Tower of the Americas �+

W. Vietnam Veterans Memorial �

S1. Dick’s Merchandise ShopS2. Food CourtS3. Rivercenter Mall �+

S4. South Bank �+

S6. Alamo Harley-Davidson Boutique

SV1. Alamo Visitors Center �SV1. Alamo Plaza SpaSV2. Amtrak Station �+

SV4. Bexar County Courthouse �+

SV5. Bus Station �SV6. Chamber of Commerce �+

SV7. City Hall �+

SV8. Convention Center �+

SV9. Little Church of La VillitaSV10. Main Library �+

SV11. Mexican ConsulateSV12. Paseo del Rio AssociationSV13. Post Office �+

SV14. RiverWalk Street Car StationSV15. Southern Pacific/Amtrak �SV16. Universidad Nacional

Autonoma de MexicoSV17. USO Information Center �+

SV18. Villita Assembly Hall �+

SV19. Visitor Information Center �

1. Acenar2. Biga on the Banks3. Boudro’s*4. Cafe Ole!*6. Casa Rio �+

26. Citrus Restauant8. County Line Bar-B-Q �+*5. Coyote Ugly �+

9. Dick’s Last Resort*10. Durty Nelly’s Irish Pub*18. Esquire Tavern8. Hard Rock Cafe �+

7. Hooters �+*11. Hyatt Regency River Walk �+

10. Ibiza Mediterranean Patio Restaurant & Bar �+*

9. Joe’s Crab Shack*12. La Margarita �+

13. Landry’s Seafood House14. Las Canarias25. Little Rhein / Fig Tree4. Lone Star Cafe �+

28. Mad Dogs16. Mi Tierra Cafe & Bakery �+

4. Michelino’s Italian Restaurant5. Original Mexican �17. Paesanos9. Polly Esther’s Dance Club �23. Pico de Gallo �+

19. Rio Rio Cantina20. Schilo’s Delicatessen �+

10. Tex’s River Walk Sports Bar21. The Republic of Texas27. Waxy’s Pub15. Zuni Grill �

E1. Howl at the MoonE2. Hyatt Regency �E3. Lila Cockrell Theater �+

E4. Majestic Theatre �+

E5. Municipal Auditorium �+

E6. Rivercenter Comedy Club �+

SHOPPING

ATTRACTIONS

SERVICES ENTERTAINMENT

FOOD & DRINK

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SV13

SV19

SV5

SV7

SV4

SV10

SV11

SV18

SV17

SV14

SV6

SV8

SV16

SV15

SV9

SV1

©Paseo del Rio Association, 1997

S1

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To see your business listed,please call 227-4262

SV12

DruryInn

Amtrak Stat ion

West in RiverwalkP

E1

2

1 • Homewood Sui tes

Hotel Valencia •

www.thesanantonioriverwalk.com

KEY:� ADA compliant places �+ ADA compliant restrooms�(P) Partially ADA compliant* Denotes various locations

Handicapped ramp or elevator to the River Walk

Parking GaragesPublic restrooms P

The Official Map of the River Walk

Legend to map:

O

SV2

20

16 23

S3

RIO PLAZA

25

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Rio2006SeptMapOnlyq5 9/7/06 2:37 PM Page 1

ATRA's Powertrain Expo, so much to do!San Antonio Convention Center

September 9-12, San Antonio, TX , pg 44,http://members.atra.com

2 GEARS August 2010

It’s time once again to make your arrangements to attend this year’s ATRA Powertrain Expo. I really

believe that this will be one of the best ever! It’ll certainly be the biggest, because everything’s bigger in Texas… or so I’ve heard.

The host hotel sits right on the San Antonio Downtown River Walk; a quiet, shady walk along a scenic water-way. And there’s a lot to do and see along the River Walk. The Alamo, the number one tourist attraction in Texas, is only a block away from the hotel. It’s well worth the visit, if only so you’ll have something to remember.

If it’s nightlife you’re interested in, no other place can match the attrac-tions found along the River Walk. Night clubs, restaurants, shops, and more all line the Walk, with something for everyone.

If you have a taste for fine din-ing, Ruth Christ Steak House is just a couple blocks away; or, for a real thrill, head over to the steak house at the top of the Tower of The Americas. This 750-foot-tall tower features a revolving restaurant and an observation deck at the top.

Also along the River Walk you’ll find a Hooter’s, a Hard Rock Café, and a Tony Roma’s — ribs, seafood and steaks. And for those of you who just like to party, there’s Coyote Ugly, Joe’s Crab Shack, Mad Dog’s, and Dick’s Last Resort.

For your stay we’ve made special arrangements with the San Antonio Marriott River Center, an elegant hotel located right on the River Walk. We’ve

negotiated a special room rate of just $149 per night for Expo attendees. Call 1-800-266-9432 to make reservations and give the code ATRA.

Like the previ-ous Expos, we’ll tee off on Thursday with the 7th Annual Red Girdey Memorial Golf Tournament. Friday evening is the ever-popular Transtar Reception; a treat for the senses and an opportunity to visit with friends you haven’t seen since last year.

On Saturday evening, plan on attending the Discover San Antonio group tour. This will be very much like the tour we took during the Washington, DC Expo back in 1997. We took a bus tour of DC from the host hotel to the magnificent and historic Union Station, and then had dinner in a lovely Italian restaurant right there in the station.

This year we’re heading out to the Rio Cibolo Ranch for a Texas-style BBQ dinner and an evening of entertainment, including line dancing and hay rides. Now this is Texas, so dress accordingly; make sure you’re decked out in your best Western ware: Wranglers, Tony Lama boots, cowboy hats, and extra-large belt buckles. If you have a problem finding a belt buckle large enough, you can always

strap on a hub cap!There’s one issue I’d like to touch

on: This year, Expo coincides with Rosh Hashanah, the Jewish New Year. The Board of Directors wasn’t aware of this conflict when we agreed to book San Antonio. It was never our inten-tion to disregard or insult anyone. The last time we had this conflict was in the early nineties, so it’s certainly not a common occurrence, and it’s some-thing we’ll do our best to avoid in the future. This was the only date avail-able in San Antonio where we could have the Marriott and the San Antonio Convention Center.

In 2008, my high school class had its reunion in San Antonio at the River Walk. Everyone had a terrific time and said they’d look forward to returning in the future. It’s an inexpensive venue, and truly a wondrous place to visit. I look forward to seeing you there!

by Jim Rodd,ATRA Board President

members.atra.comwww.atra.com

FROM THE PREsidEnT

Expo 2010; San Antonio, Texas

Whatever It Takes Does!!!

72 72

www.wittrans.com

45RFE / 5-45RFE RWD 4 & 5 Speed

© Whatever It Takes Transmission Parts, Inc.

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1-800-940-0197 • www.wittrans.com

4 GEARS August 2010

As a football coach, I often find myself repeating a familiar saying: “the cream always rises

to the top.” In other words, the best players will always outshine the more average players. I consider this a valid commentary when discussing transmis-sion technicians and the automotive industry. Transmission techs are the cream of the crop… the best of the best… and that’s the way it’s always been.

As long as I can remember, trans-mission repair has been a specialty, a job that most technicians wouldn’t touch with a ten-foot pole. Not that they didn’t want to; they were just plain afraid of those magic boxes between the engine and the differential.

For the rest of the repair industry, that part of the car was a question mark; a blank area that just plain worked or it didn’t. They had no idea of why or how. Yet you made the decision to dive head-first into transmission repair. That’s what makes you the cream of the crop.

I realized long ago that I needed to be in the automotive industry. I was five years old, beating on a Tonka™ Truck, and as I was wielding the ham-mer, it smacked me on the head. I don’t think it knocked sense into me, but it did give me a sense of things to come.

At seventeen I graduated high school and went to work for Ford. I started working on transmissions at nineteen and finished every class Ford had to offer by the time I was twenty eight.

There was something that struck me early in my career… besides the hammer: For a person to learn some-thing, he needs three things:

1. Kinesthetic (touch and feel)2. Audio (sounds)3. Visual (sight)I was good at the kinesthetic parts

of the job. I was good at the audio parts, too: Tell me what to do and I’ll do it. But visual had me at a loss. I was never a very good reader; in fact, when it came to reading, if I didn’t have to do it, I wouldn’t. And in most cases, I could figure out what I needed to know from the picture, or by touching the part enough times to understand it.

All of that changed when I turned nineteen. I received a wake-up call and a challenge: That’s when Ford introduced its new warranty policies. Suddenly there were categories that you had to be trained for or you don’t get paid! The categories were:

• Electrical• Electronics• Driveability• Engine• Transmission• Brakes/Front EndIt took me over nine years, and

about 4200 miles of combined travel, to finish every class. I did it because I have the same drive that you have: the drive to be the best of the best, the

cream of the crop. I don’t think I’d have done it on

my own. But I was being pushed… I was challenged. And I rose to that chal-lenge. Now, some twenty two years later, we’re being challenged again.

We’re all aware of the new tech-nologies that are out there today. And there are a lot more coming down the pike, soon to find their way into your shop. This is the time to get a leg up and prepare for those technologies, before they start coming after you with a big hammer.

This is your chance to maintain that advantage over the other shops, by signing up for training at the only pro-gram in the world that’s tailored exclu-sively for you: ATRA’s Powertrain Expo.

This year we’ve signed with some of the leading industry trainers to bring you the understanding and know-how to handle the transmissions that are already knocking at your door.

Make your plans for San Antonio, Texas, September 9th through 12th. Come and gain that valuable insight that’ll catapult you to the top of our industry… and keep you there. There’s no doubt in my mind that you’re the best of the best: now’s the time for you to rise to the top!

I look forward to seeing you there, reconnecting with you, jockeying sto-ries back and forth, and catching up with some old friends. And if you can’t make it, I understand, but do me a favor: Promise yourself to continue to face the challenge… to be the cream of the crop… the best of the best! It’s what we’re all about.

by Lance Wigginsmembers.atra.com

www.atra.com

FROM THE TEcHnical DiREcTOR

The Cream of the Crop

get a leg up and prepare

for those technologies,

before they start coming

after you with a big hammer.

SPEAKER

711 Tech Drive, Crawfordsville, IN 47933 • Toll Free: 800-729-7763 • Fax: 765-364-4573 • Email: [email protected] www.raybestospowertrain.com

An OE Secret about the 911 PorschePssst… Do you know why the shifting performance of the 911 Porsche is, well, unbelievable? Because it’s engineered to perfection, down to the OE Dual Clutch Friction Plate by Raybestos Powertrain.Raybestos Powertrain has been the OE supplier to automotive manufacturers all over the world since 1938. We begin with superior engineering to deliver the performance you demand. It’s no secret – there’s no substitute for Raybestos Powertrain transmission parts!

6 GEARS August 2010

Back in 1969, Borg-Warner formed a joint venture with Aisin Seiki to form Aisin

Warner. We first got a taste of these transmissions when we started working on the early Toyotas.

Fast forward to today: We’re working on lighter, more efficient transmissions than ever before. Aisin Warner (AW) produces a 6-speed, front wheel drive in two basic versions: the TF-80SC and the TF-60SN.

Now some may ask why the guy who always talks about Ford transmis-sions is bringing this foreign unit to his seminar.

The answer is simple: The TF-80SC comes in the 2006-and-up Ford Fusion, and the Mercury Milan and Montego. The Fusion was named Car of the Year for 2010 by Motor

Fun with transmissions

The Aisin Warner 6-Speed to San Antonio by Bill Brayton


We’re working on lighter, more efficient trans-missions than

ever before. Aisin Warner

(AW) produces a 6-speed, front

wheel drive...

Figure 1B: Early VW body with Pressure Switches.

Figure 1A: Later style valve body without switches

SPEAKER

8 GEARS August 2010

Trend magazine, so we know this is one popular automobile.

Besides the Ford model, the TF-80SC is also used in the Volvo S60R and the 90 series. Another varia-tion, the TF-60SN, known as the 09G, is used by Volkswagen and Audi.

As with any new unit, we go through the experiences of finding out exactly where the weak points of the unit are.

In San Antonio, we’ll discuss one of the major weak points: the valve body (figures 1A and 1B). We’ll look at where the weak points are and what can be done about them.

Did you know that the early VW valve body with the pressure switches will interchange directly with the later non-pressure switch valve body? This may come in handy in a pinch.

The hard parts from the AWF-21 and the 09G aren’t interchangeable, so we’ll look at some major hard part differences and their typical failures (figures 2A and 2B).

Scanning a Ford product is pretty straightforward. Most of us already have that capability. But what about reprogramming? What about the VW scan tool? We’ll explore different options and different scenarios that involve these scan tools.

Come to San Antonio for a great learning experience, and take that knowledge back to your shop, where you can use it to have more fun with transmissions!

Figure 2A: AWF-21B Pump Assembly

Figure 2B: 09G Pump Assembly

Scanning a Ford product is pretty straightforward.

Most of us already have

that capability. But what about

reprogramming?

I bet my dad I could get four new distributorsin 2010, and I’m halfway there! We welcomedSnider’s West in The Quad Cities area of Illinoisand Iowa to the Certified family. The CertifiedTransmission Program is unique, designedexclusively for professional transmission shops(or: auto and truck repair shops) looking toincrease capacity, sales and profits. More thanjust another reman unit, Certified transmissionsare installed by the people who build and testthem and by professional shops throughoutNorth America.

� A designated territory� 200 of your fastest moving transmissions

in stock at your location� 5,000 more transmissions and transfer

cases just a phone call away� A program allowing you to pay for them

after you sell them

� Attract more fleet and general repairbusiness with immediate delivery

� Able to offer same day service again(At a premium price)

� Free use of the copyrighted andproprietary Certified TransmissionVehicle Specific Lookup ID system

Call Terry Cash at

800-544-7520 ext.170

Join the Network of SuccessAkron, OH Waterloo Transmission 800-824-6689Baltimore/

Washington DC Glen Burnie Transmission 410-766-8500Boston, MA Metro Transmission Distributors Inc 800-891-5508Casper, WY Auto Dynamics 800-222-4646Des Moines, IA All Drive Transmission 800-247-1499Dubuque, IA Precision Transmission 563-585-0270Framingham, MA Bonded Transmission 508-872-1119Ft. Dodge, IA Certified Transmission Iowa 800-362-2189Kalona, IA Kalona Auto 800-728-3098Kansas City, MO Certified Transmission Kansas City 800-544-7520Kieler, WI Shift Point Transmission 608-568-3054Madison, WI Trans Works Transmissions 608-742-5136Minneapolis, MN Tri Star Engine & Transmission 800-322-5859Manhattan, KS Stagg Hill Transmissions 785-539-2900North/Central NE Norfolk Transmission 800-234-8726Omaha, NE Certified Transmission Nebraska 800-544-7520Philadelphia, PA Metro RMP 800-257-7418Quad Cities IA/IL Snider's West 563-391-7534Rapid City, SD Logan's Transmission 800-579-1742St Louis MO JC Parts City 866-735-1960Salt Lake City, UT Freeway Transmission 800-354-5920San Diego, CA Metro Certified Transmission of So. Cal 888-374-8383Scottsbluff, NE Wilburn's Transmissions Inc. 308-635-1212Sioux Falls, SD J & M Transmission 800-504-2050Tulsa, OK Eddie's Transmissions 918-272-6683Youngstown, OH/

Tri -State Redlich Transmission 330-758-555

www.certifiedtransmission.com

W A N T N E W R E V E N U E F O R Y O U R B U S I N E S S ?

PARTNERSHIPPRODUCTIVITYPROFITABILITY

Peter and Amanda FinkCertified Transmission

I’m Halfway there Dad…2 new distributors!

CT-GearsMag5Final-5'10:Layout 4 5/25/10 2:23 PM Page 1

10 GEARS August 2010

by Pete Huschermembers.atra.com

www.atra.com

Keep Those Tranny’s rollingQuattro and 4Motion: Volkswagen Group’s Answer to All-Wheel Drive

What this article needs is backround images added and creative use of space, can you see a way to make it flow into these 4 pages? Backround images are on the left. Please put in captions and add color. Please see sample pages at gearsmagazine.com

The Volkswagen Group has been

developing four-wheel drive

vehicles sincebefore the second World War, where

they developed the Kubelwagen, Schwimmwagen, Kommandeurwa-gen (all 4x4 ve-

hicles), and even a four wheel drive

Volkswagen Beetle. In this issue of Keep Those Tranny’s Rolling, we’re going to look at the AWD systems offered

by the Volkswagen Group.One of the most commonly known

AWD systems from Europe is from the Volkswagen Group, which manufac-tures Audi and Volkswagen vehicles. The AWD system used by Audi is known as the Quattro system and the AWD system used by Volkswagen is known as the 4motion system.

The Volkswagen Group has been developing four-wheel drive vehicles since before the second World War, where they developed the Kubelwagen, Schwimmwagen, Kommandeurwagen (all 4x4 vehicles), and even a four wheel drive Volkswagen Beetle.

The Volkswagen Iltis, which was designed in the 1970s for the German military, used an early form of four

wheel drive that would later become known as Volkswagen’s Quattro sys-tem.

The Volkswagen Group uses two different types of AWD systems: the longitudinal system and the transverse system, depending upon engine and transmission orientation.

Longitudinal SystemsThe early Quattro systems, starting

with the 1978 Audi 80, were permanent, four wheel drive systems, equipped with a manually lockable, open center

differential (more commonly known as a transfer case or power take-off unit), a manually lockable, open rear differ-ential, and a non-locking, open front differential. These were known as first generation systems.

In late 1987, Audi replaced the manually-locking, open center differ-ential with a Torsen Type 2 (short for torque sensing) center differential (fig-ure 1). The Torsen carrier assembly works basically the same as a limited slip differential: It distributes the torque difference between the output shaft with the least amount of traction avail-able and the output shaft with the most traction available.

GEARS August 2010 11

Figure 1: Quattro’s Torsen Centre Differential

What this article needs is backround images added and creative use of space, can you see a way to make it flow into these 4 pages? Backround images are on the left. Please put in captions and add color. Please see sample pages at gearsmagazine.com

The Torsen coupler supports a stat-ic torque ratio split of 50% to the front axle and 50% to the rear axle, and is capable of a torque ratio split of 33% to the front axle and 67% to the rear axle under aggressive driving conditions.

These were permanent four wheel drive systems, equipped with a Torsen center differential, a manually lock-able, open rear differential, and a non-locking, open front differential. This all wheel drive system is controlled by the ABS and is known as a second genera-tion Quattro system.

In 1990, Audi replaced the locking rear differential with a Torsen type rear differential. A planetary set was added to the Torsen center differential for all V8 Audi Quattros with automatic trans-missions. Audi Quattros with manual transmissions came equipped with a Torsen center differential and a Torsen-type rear differential. Both models con-tinued to use the open front differential. This version of the Quattro system was referred to as third generation.

In 1995, Audi replaced the manu-ally locking, open differentials with a newly designed Electronic Differential Lock (EDL) open differential system. The EDL system detects wheel slip by monitoring the ABS wheel speed sensors, and then gradually applies the brakes to the slipping wheel, allowing torque to be transferred to the opposite wheel.

This forth generation system con-tinued to use the Torsen T2 center differential. This system was also intro-duced on the 1995 Volkswagen Passat, where it was initially referred to as the syncro system. It was finally renamed the 4Motion system. Volkswagen con-tinues to use the 4Motion name for its all wheel drive systems. This system is referred to as the fourth generation of the Quattro system.

Beginning in 1996, Audi replaced the Torsen T2 center differential with a new design Torsen T3 center differen-tial. The Torsen T3 center differential combines a planetary set with a Torsen differential. Unlike the Torsen T2 car-rier, the Torsen T3 carrier torque split is closer to 40% to the front axle and 60% to the rear axle. With 60% of the torque being sent to the rear axle, the Torsen T3 system provides a rear wheel drive

type feel.The Torsen T3 system continues

to use an open rear differential with Electronic Differential Lock, and an open front differential also equipped with the EDL system. The Torsen T3 system is referred to as the fifth genera-tion of the Quattro system.

Audi’s sixth generation Quattro system is known as the Quattro Torque Vectoring System (figure 2). The torque vectoring system was built by ZF Manufacturing under the name Vector Drive, and is being offered on the Audi

A4, A5, A6, Q7, and Q5.The Quattro Vectoring System still

uses the Torsen T3 carrier in the center differential. The open rear differential with the EDL system has been replaced with an electronically controlled Active Sport Differential. This new system continues to use an open front differ-ential equipped with the EDL system.

Transverse SystemsThe Volkswagen Group considered

adding an all wheel drive system to their A-platform cars back in 1974. But

Figure 2: Quattro’s Torque Vectoring System


Quattro and 4Motion Continued

it didn’t seem to materialize until the second generation of A-platform cars in the mid-1980s.

The A-platform cars had a trans-versely mounted engine and transmis-sion with a power take-off unit (PTU) mounted to the side of the transmission. The purpose of the PTU was to deliver driving torque to the front and rear axles. The rear drive axle was equipped with a viscous coupler to minimize driveline windup or binding.

This viscous coupler type all-wheel drive system was found on the Golf, Jetta, Vanagon, Passat, and Eurovan. The viscous coupler system was only used on Volkswagens; never on any Audi vehicles. This early system was known as the syncro system.

The Haldex SystemIn 1998, Volkswagen replaced the

viscous coupler system with the Haldex Traction LSC system, which uses an electronically controlled, hydraulic, limited-slip coupler in place of the vis-cous coupler (figure 3).

The Haldex Traction LSC system was an option on the Audi A3, S3, and TT models under the Quattro name. It

Haldex AWD

systems are

currently being

used by several

automotive manu-

facturers such as

the Volkswagen

Group, Volvo,

Saab, Land Rover,

Bugatti, General

Motors, and Ford

Motor Co.

was also available in the Volkswagen Golf, Golf R35, Jetta, Sharon, Passat,

and Transporter T5 models under the 4Motion name.

Haldex AWD systems are current-ly being used by several automotive manufacturers such as the Volkswagen Group, Volvo, Saab, Land Rover, Bugatti, General Motors, and Ford Motor Co.

The Haldex Traction LSC sys-tem is controlled by the Haldex ECU (figures 4 and 5). The Haldex ECU uses information from the ABS control module to control the AWD system. This system attempts to engage the rear drive axle when it detects front wheel slip.

The Haldex ECU engages and dis-engages the Haldex clutch as needed to allow the ABS system to operate prop-erly, and to prevent driveline binding during tight turns. The mechanical front and rear open differentials were replaced with front and rear, electronically con-trolled, open differentials (EDL).

This system uses the ABS and sta-bility ride system to control the AWD system by applying the brakes to slow the wheel with the least amount of trac-tion.

Figure 3: Haldex LSC System Components


Figure 4: Haldex’s Traction LCS System

Diagnosing the AWD Systems

Diagnosing the Audi and Volkswagen AWD system is pretty straightforward. The AWD systems are controlled by the ABS control mod-ule and Haldex ECU (if equipped). Diagnosing the ABS and Haldex system will require using a VAG or compatible scan tool that’s capable of accessing the ABS control module and the Haldex ECU.

Once you have access to the ABS control module and the Haldex ECU:

• Retrieve and document all codes stored in the both modules.

• Clear all codes from the ABS control module and Haldex ECU, and recheck the AWD system operation.

• IfABSorHaldexsystem codes return, diagnose and repair these codes as needed.

• Ifnodiagnosticcodesare present and you continue to experience AWD system problems, inspect the AWD

components.

Remember to check the basics: check and compare tire sizes, circum-

ferences, and tire pressures. If every-thing looks good, you may have a mechanical problem with the center, rear, or front differentials. Inspect andrepair as needed.

Well, there you have it: an inside look at what makes the Quattro and 4Motion AWD systems operate. With a better understanding of how these

AWD systems operate, you should have no problem keeping those tranny’s and AWD systems rolling.

Figure 5: The Haldex ECU

Quattro and 4Motion Continued


The RE5R05A: A Deeper Look

by Mike Souzamembers.atra.com

www.atra.com

If it weren’t for a radiator fail-ure causing antifreeze to enter the transmission, the RE5R05A

might have made a quieter entry into the automotive industry. Reminds me of a problem Nissan was having with radi-ators a few years ago: at least they’re consistent.

In this article we’re going to touch base on some of the information that’ll be presented at this year’s Expo in San Antonio, Texas, on September 9th to

the 12th.The RE5R05A, also referred to as

the JR507E, was first introduced in the US in 2002 in the Infiniti Q45. Since then, it’s made its way into the Nissan line in 2004 and the Kia Sorento in 2005.

In mid-2004, the Transmission Control Module (TCM) was moved into the transmission. If you take in a 2004 RE5R05A with antifreeze contamina-tion and you don’t change the TCM

(figure 2), the vehicle may return in a couple days or weeks with ghost codes for solenoids that have nothing wrong with them.

The female terminals on the sole-noids can lose tension, which can also set codes, even on new solenoids. So always check those terminals when rebuilding or repairing these units.

In addition to TCM contamina-tion, the pressure switches on the TCM (figure 3) can also set ghost codes.

Figure 2

Figure 1

SPEAKER

The RE5R05A, also referred to as the JR507E, was first intro-duced in the US in 2002 in the Infiniti Q45.

Figure 3

GEARS May/June 2010 17

Figure 4

P0731 ratio error in 1st has been caused by a false signal from pressure switch 2 (low coast brake). The pressure switch-es on the earlier system are part of the internal harness (figure 4).

Be careful when exchanging valve

bodies: In the earlier valve body (figure 5), the neutral-reverse (N-R) accumula-tor springs are installed first; then the pistons. There’s also an empty valve bore next to the direct clutch piston switching valve.

In the later valve body (figure 6), the N-R accumulator pistons install first, then the springs. They also added a direct clutch regulating valve in the bore that was empty on the earlier mod-els. There are also checkball location

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Figure 5

Figure 6

RE5RO5A Continued

differences, so these valve bodies aren’t interchangeable.

There are several pitfalls associated with this transmission, such as crossing connectors that may cause blown fuses

and set codes, swapping planets with the wrong ratio, and differences in input shafts and converters.

All these subjects plus many more will be discussed at the Expo in San

Antonio in September; I look forward to seeing you there!

SUPPLIERMEMBER

Celebrating 50 years in the transmission industry!


It’s Time to Shift Gears; The Magna Powertrain Transfer Case by Steve Garrett


Well, it’s that time of year again; time for your annual pilgrimage to the ATRA

Powertrain Expo! What’s new for this year? For one thing, this year’s Expo is going to be in San Antonio, Texas.I’ve been to San Antonio many times; in fact, the last time I was there I took my wife. You may wonder why I’d drag my wife to central Texas for an ATRA seminar. The answer’s simple: San Antonio and its surrounding area is one

of the neatest places I’ve ever been to. So, if you were wondering whether you should go or not, I can tell you that you’ll regret it if you decide not to attend this year’s Expo. And, after your wife finds out how terrific this trip was from the other wives that attended, you’d better get ready to start sleeping on that cot in your shop. So what exciting material will I be presenting this year? I’ll be doing a presentation on the Magna Powertrain transfer cases that made their way

into the market starting in 2007. The MP transfer cases replaced the New Process/New Venture transfer cases you’ve grown so familiar with through the years. A number of MP transfer cases are now on the market, in use by several manufacturers. The GM family of transfer cases includes manually controlled models 1222/1225/1226, electrically shifted models 1625/1626, and active transfer case models 3023/3024.

Figure 1

SPEAKER

GEARS May/June 2010 21

As you can see there are seven different transfer cases just for GM applications. What’s so different about these units? In a nutshell, the construction of the units is very similar to the NV design transfer cases you’ve worked on for years. But the internal operation of the shift mechanism is quite different from most pervious designs. MP units use a completely different design shift motor (figure 1). In addition, this new design shift motor requires a learn process to adapt to system condition and wear. You’ll have to initialize a relearn process if you replace the motor. What about diagnostics? They’re different too, because the electronics on this unit aren’t the same as they were on the NV units. In fact, many of the components that you’ve become so accustomed to over the years, such as the encoder assembly, aren’t being used any more. Are you curious yet? I hope so: change is good in our industry, and it’s always good to have a bit of curiosity regarding the products entering the market. Remember, your competitor who didn’t attend this year’s Expo probably won’t know this change even occurred, let alone how the diagnostics and service procedures have changed.So, while your spouse is having the time of her (his?) life in San Antonio, you can be preparing yourself for the future when it comes to servicing MP transfer cases. I hope to see “y’all” there!


Once in a while an opportunity comes along that compels you to share your experiences with

others dealing with the same issues. In this case we had a number of issues with a late Volkswagen Beetle and the infamous 09G 6-speed automatic transmission.

Checking TCC Command To check the TCC command from the TCM to the N91 solenoid, you’ll need to access the wiring near the TCM. The TCM is mounted under the passenger side of the dash. To access it, you have to release the top center panel of the dash; push it forward and then pop it up to release it (figure 1). To protect the other dash panels, I removed the right side dash end cap, the glovebox assembly, and the passenger hold-on bar and dash panel that covers the passenger air bag canister. Then I unsnapped the A-pillar interior trim panel and popped out the passenger side top dash panel (figure 2) There was another panel under that one, mounted with a few more screws and held down with press-in tabs. Figure 1: Removing the center dash cap

Figure 2: Removing dash panels to access the TCM

Finally I accessed the TCM (figure 3) and connected a Vantage graphing meter to the TCC command wire. It displayed about 5-10 percent with no TCC apply. After 3rd gear it started to ramp up to 40-60 percent at about 30-45 MPH, depending on load. At highway speeds it commanded a duty cycle of around 75-90 percent.

Figure 3: Locating the TCM

by Dave SkoraTechnical Director,

Valve Body Pro

C M Y CM MY CY CMY K


Figure 5: Modus Expert Mode on the engine side Figure 6: Entering block value code 063 for base setting

Pressure Tap Locations I also connected gauges to the various taps. The lube tap had about 2-3 PSI at idle and varied between 6-30 PSI at 40 MPH, again depending on vehicle load. The K1 tap for forward engage-ment measured between 45-55 PSI, depending on which valve body we were testing. Reverse pressure at idle in the B2 tap was about 75-85 PSI. At stall, reverse pressure went up to 280 PSI. There are some tap location errors out there in articles published on this unit: The K1 tap is located at the forward lower left side of the case. The B2 tap is

located on the left side, midway up the case (figure 4).

Adaptive Strategies These vehicles have very sensitive adaptive shifts; after installing a valve body, you must perform the base setting before the transmission will shift properly. First make sure that all modules are working and no codes are present. The vehicle should be at normal operating temperature, and the battery and vehicle electrical system must be in good condition. There should also be at least 3-4 gallons of fuel in the tank. ATRA’s Bill

Brayton explained that adding fuel to a Beetle solved some harsh engagement issues that one ATRA Member was having. Here are some screen shots from a Modus scan tool with 2009 software. We were able to perform the base setting by accessing EXPERT MODE under the engine side (figure 5). The scan tool pretty much prompts you through, except for a few areas. To access the base settings, the scan tool asked us to enter a block value code. We used code 063 (figure 6); when you get to the screen for base setting, you have to hold the throttle all the way

A Closer Look at VW's Continued

Figure 4: Left side of 09G transmission

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Figure 7: Base setting screen after holding the throttle to floor for 3 seconds. Figure 8: Disassembled solenoid with weak coil.

open for 3 seconds (key on, engine off; figure 7). When you release the throttle, the screen should change to OK.

Valvebody Test: Harsh Engagement One valve body we tested created very harsh engagements right away. Except for that, it always drove and shifted great, cold or warmed up. After the base settings were completed, forward engagement smoothed out but reverse remained harsh. We drove it again on city streets and at highway

speeds. The only issue remained was reverse engagement. This was an interesting problem because I knew the vehicle and transmission were good. I remembered a fix for the 5R55N used in the old Lincoln LS for a delayed Reverse. To fix this one, I moved the gear selector slowly out of reverse. As soon as I felt the clutch begin to re-lease, I dropped it right back into reverse. I did maneuver this about 3 times. After that, reverse engagement was perfect.

Valvebody Test: Delay in Reverse and Flare into 3rd and 5th This valve body started acting up right away. It caused a delay and a bang in reverse, and a flare-bang into both 3rd and 5th. We knew this could only be caused by a bad solenoid or the valve that controlled the K3 clutch. We removed the N90 solenoid, which controls the K3 clutch. N90 is the large solenoid next to the manual valve. Be careful; some published information lists the wrong solenoid controlling the

A Closer Look at VW's Continued


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Figure 9: Filling the pan with fluid. Figure 10: Pumping fluid into the transmission at the harness connector.

K3 clutch. NOTE: You can remove this solenoid by either removing the whole valve body, or by removing most of the bolts and loosening — but not completely removing — the valve body bolts from the opposite side of the solenoids. I disassembled the solenoid down to the coil (figure 8). Everything looked good: the armature was free and the valve wasn’t sticky or worn. The coil resistance was at 5.4 ohms. But remember, resistance can only verify

whether something is bad. It can’t tell you whether a device or circuit will work well under live conditions. I got another solenoid coil and installed a special alloy bushing to replace the suspect one. Guess what? It worked. The delay in reverse and the flare-bang shifts completely went away. We were happy to be able to change one weak solenoid and help a shop out.

Filling the Transaxle One last tip we’re glad to pass along concerns adding fluid. There’s a

small fill tube on the front of the case, but it’s hard to get to and requires a very small funnel to add any fluid to the unit (figure 9). We discovered that, by removing the wiring harness pass-through connector on the front corner of the unit, there was enough slack in the wiring to insert a tube and pump fluid into the transmission (figure 10). Until next time, keep your mind open to new ideas and your bays full.


Most workplace injuries involve workers who have been on the job for the less

than one year, many have been on the job for less than 30 days. New work-ers may be experienced in another line of work or they may just be coming out of school with very little, or no job knowledge. They may not be aware of the hazards they could face in the work-place or the proper safety procedures to follow that would help to protect them.

It is the responsibility of the employer to provide training that will enable workers to perform their jobs in a safe, efficient, and productive man-ner, while also complying with the regulations and standards that apply to their industry.

A commonly overlooked part of safety training is the language bar-rier. This issue may go unnoticed, as few workers won’t admit they do not understand job instructions being given by the employer. However, not being able to understand safety instructions can quickly lead to work injuries, incor-rect machine operation or problems with production, quality or compliance. Therefore, the trainer must make sure every worker understands the training material; not just that a worker was present.

It is vital that workers understand the purpose of the training, why it will be of use to them, and the consequences of not following safety rules and pro-

cedures. Training material should be organized so that the order in which the material is presented will match the safety procedures that are to be fol-lowed on the job.

The most effective safety training starts from the day the worker is hired. A good place to start is by explain-ing the company’s Injury and Illness Prevention Program (IIPP). The IIPP “training umbrella” requires workers to be trained in two major areas:

• General safety - areas that affect all employees such as fire drills or other emergency procedures

• Specific training - for the hazards associated with the employee’s job assignment

All training, no matter how brief, should be documented and should be placed in the employee’s file or training log. Training is required:

• For all new employees, and employees who have been transferred to a new job activ-ity

• Whenever new hazards are introduced (chemical or physi-cal)

• Whenever new hazards are recognized, such as an updat-ed Material Safety Data Sheet (MSDS)

• For supervisors to familiarize themselves with the safety and health hazards of employees under their supervision

Now is a good time to review training requirements and be aware that annual training may be required for certain activities or hazardous expo-sures. To learn more about the training requirements for your particular work-place operation, check with your State Fund Loss Control Consultant or Cal/OSHA.

Day One: Safety Training

by State Compensation Insurance Fund

The most effective safety training starts from the day the worker is

hired.

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Quantity plus qualityFrom the latestmakes andmodels to the oldest and everything in between, we have asolution to virtually every transmission repair problem. They’re guaranteed towork, too.All are cross-checked against OEM specs. All changes are noted andmade. Andwe alwaysuseOE parts or better. Plus, with our huge inventory and state-of-the-art warehousingcapabilities, we’ll deliver exactly what you needwhen andwhere you need it.

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So the next time you need a transmission repair kit, don’t get boxed into a corner.Draw fromPrecision International’s vast experience and product line.Formore information, give us a call.

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209-PRE-081 Transmission Digest....02/10/10 L: 7.375x10.125 T: 8.125x10.875 B: 8.375x11.125 4CGears Magazine..........Mar 2010

209PRE-7.375x10.125-081:Layout 1 2/9/10 12:44 PM Page 1

30 GEARS May/June 2010

The 2010 ATRA Expo is right around the corner. Each year I look forward to Expo, not only

for the learning experience, but to catch up with friends and meet new people in our industry. And this year’s Expo will be our first time in San Antonio, Texas. I can’t wait!

Each year I try to focus on the Chrysler/Dodge line of automatic

transmissions and transaxles. Over the years we’ve discussed diagnostic rou-tines and build information, as well as updated parts for the RE (42, 44, 46, 47, and 48RE) family of transmissions, the TE/AE/LE/RLE family of transmis-sions (40, 41, 42, and 62 series), the full RFE (45, 5-45, and 68RFE), and the AS68RC lineup.

This year we’ll continue our

Chrysler/Dodge theme by focusing on the Continuously Variable Transaxle (CVT): how it works, as well as diag-nostic and rebuild procedures when dealing with this high dollar unit.

The concept of replacing an auto-matic transmission with a CVT began near the end of the 20th century, only to be sent back to the drawing board because they just wouldn’t hold up to

by Randall Schroedermembers.atra.com

www.atra.com

Doctor. Doctor It Hurts When I Shift…

Understanding the Dodge Family of CVT Units

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the demands of everyday driving.Technology and materials have

changed and the durability problem has been overcome, even when coupled with today’s high-torque engines. There are many auto manufacturers starting to use CVTs, and they’re proving to be both reliable and durable under normal driving conditions.

That durability has its limits: tow-ing creates more failures than nor-mal, and high horsepower applications (pushing the driving limits) have a tendency to burn off the belts.

Chrysler/Dodge introduced their CVT in the Dodge Caliber, Jeep Compos, and Jeep Patriot, both FWD and AWD vehicles, with the 2.0L and 2.4L engines.

The CVT unit selects the best drive ratio based on torque demand and driv-ing style. This happens by varying the size of two pulleys that push a steel belt to achieve the best overall driving ratio. This includes an extremely low ratio for acceleration, and a super high overdrive ratio for fuel economy. Compared to a unit with stepped gear ratios, such as a normal shifting transmission, the CVT typically gets about a 12% increase in fuel economy. Consumers have recog-nized the value of this and are generally sold on this economy.

There are many vehicles with these CVTs on the road today, and they’re already beginning to show up in shops across the country. So it’s important to understand how these units work.

We’ll be covering how the CVT systems function, and learning impor-tant techniques for repairing this unit. It should prove to be an exciting learn-ing experience as we go through the mechanical, electrical, and hydraulic operating principles that allow these transmissions to work.

I look forward to seeing all of you at Expo 2010 this year. Until next time, keep those transmissions in good shift-ing health!

The Doctor

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What’s Working: For the last four years we’ve been studying transmission

shops to see what makes one shop suc-cessful, while another shop, right down the road, struggles to make ends meet.

We began by collecting data, to see what successful shops have in common that other, less successful shops were missing. Then we interviewed consum-ers to discover what they expected from a repair shop.

The results from these studies were

part of the What’s Working presentation at ATRA’s Powertrain Expo. Each study provided another piece of the puzzle for business success; a puzzle that, when assembled, provided a striking image of what it takes to be successful in the transmission repair industry.

So we had an answer. But that left us with one critical question: Was it possible for a shop owner to apply the findings from the What’s Working study, and actually make a difference in his business? We didn’t know… until

now. Now we have the proof... living,

breathing proof that the information from What's Working can really make a difference in today's transmission repair shops.

People across the country are suc-cessfully applying the ideas of What's Working and this year, our panel con-sists of four past Expo attendees who took what they learned at Expo and turned their shops around. They’ll share their personal experiences for

What’s WorkingWhat’s Working

Now We Have the Proof ! by Dennis Madden


SPEAKER

... this year, our panel consists of four past Expo attendees who took what they learned at Expo and turned their shops around.


applying the principles of What’s Working into real world practices… and real world results.

Like Mario Jauregui of Express Transmissions. Think success is all about “location, location, location”? Mario’s shop sits right in the heart of what Forbes branded “The Most Miserable City in the US”! How’s that for location? But he’s built a business any shop owner would be proud of, and he credits much of his success to what he learned at Expo.

Or how about Gerald and Gary Vess, of USA Transmissions in Houston, Texas? They were recently profiled in the Strategies section of the Houston Business Journal (page 34). In it, they cite What’s Working as the inspiration that turned their business around.

Then there’s Zach Evans of Zach’s Transmission and 4X4. Zach started out at the bench, and he was running his shop that way until he came to Expo.

There he learned to think like a busi-ness owner, and it paid off.

This year, Mario, Gerald, Gary, and Zach will share how they applied the principles of What’s Working to make sweeping changes in their busi-nesses. Like many of you, they were getting by, but never enjoyed the suc-cess they wanted. Then they discovered the five recurring traits of successful shop owners:

1. 2. 3. 4. 5.

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They embraced these traits, and it changed the way they do busi-ness. They proved it can be done. They proved that acquiring these traits will have a dramatic impact on the success of your business.

So if you want to turn your business around, you need to make your way to Expo. It’s not about studies any more: It’s about results. This is where you can see what we’ve been saying in action, and you can discover just how well it works. We have the proof!

Now it’s up to you: Make your reservations today to come to San Antonio, Texas, September 9th through the 12th. These guys are put-ting their very successful shops on hold to share how they did it. They’ll answer your questions, and help you discover how to make What’s Working work for you.

And don’t just show up: Get involved! Start thinking about the questions that have been nagging you for years. How can I take advantage of community involvement? What’s the best way to advertise my shop?

Should I expand my service offerings? Whatever you want to know, someone else had the same questions. And we’re going to have a lot of great minds at Expo, to help you find the answers.

This is your big opportunity: You don’t often get to sit and talk, one on one, with guys who are turning an industry on its heels. The folks at Expo are the movers and shakers of transmission repair. More important-ly, they’re regular guys who fix cars

for a living, just like you.This is your chance to rub elbows

with the guys who are making it work. And they’re living proof that the What’s Working program really works. You may never receive an opportunity like this again: Grab it for all it’s worth… and we’ll see you at Expo!

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...they cite What's Working as the inspira-tion that turned their shops around.

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GEARS_August 2010.indd 2 7/7/2010 12:35:39 PM


The U660E first appeared in the Lexus ES350 and the Toyota Camry in 2007.

Then it showed up in the 2008 Avalon, followed by the Venza in 2009.

To diagnose and repair these transmissions, you’ll need some special tools. One tool you’ll want to have is the techstream: Toyota’s dedicated scan tool. But you don’t have to buy the actual techstream: Techstream lite is a PC-based ver-sion of the scan tool, providing you with the same access to the Toyota/Scion/Lexus computer system for a fraction of the cost.

Toyota’s transmission com-puter has a learning function to adapt transmission performance to vehicle operation. So whether you’re just replacing a solenoid or the entire valve body, part of your repair procedure should include initializing the TCM and then road testing the vehicle to give the TCM a chance to relearn.

U660E: Diagnosing the Toyota 6-Speed

Title=Bold

by Mike Brownmembers.atra.com

www.atra.com

Street Smart

Toyota’s transmission computer has

a learning function to adapt

transmission performance

to vehicle operation.

Figure 1


When performing a major repair, such as replacing the engine or trans-axle, or even the TCM, you’ll need to reset the transaxle compensation code. This is Toyota’s term for reprogram-ming the TCM. Naturally you’ll need to road test the vehicle to allow the TCM to relearn and adapt after resetting the compensation code.

To reset the transaxle compensa-tion code using techstream lite:

1. Move the shift lever to neutral

or park.2. Key off.3. Connect your techstream lite

connector to the diagnostic link connector (DLC3).

4. Key on, engine off.5. Turn your computer on, and

enter the techstream lite pro-gram.

6. Enter the menu items in this order:• Powertrain

• ECT• Utility

7. A/T Code Reset.8. Select Next to proceed.9. Select Exit.10. Perform road test to allow the

TCM to adapt to the transaxle and conditions.

Transaxle Compensation Code (figure 1).

Transaxle compensation codes are

Figure 2


unique, 60-digit alphanumeric values printed on the QR label on the trans-axle. The code provides the computer system with the initialization informa-tion for that transaxle configuration.

Entering the wrong transaxle com-pensation code into the TCM will cause shift shock.

After you’ve installed the trans-axle, the QR code label will be out of position, where you can’t read it. So always record the transaxle compensa-tion code before installing the transaxle.

The chart (figure 2) shows you which procedure will be necessary, depending on which repairs you per-formed.

Diagnostic ProceduresToyota and Lexus use a large num-

ber of ECU-controlled systems. These systems are often very intricate, requir-ing a high level of technical knowledge to troubleshoot.

But most diagnostic procedures only involve inspecting one circuit at a time. With a basic understanding of the system and a firm grasp on the prin-ciples of electricity, you should have no trouble performing accurate diagnoses and repairs.

Shift Solenoid OperationThe TCM commands shifts by

turning the shift solenoids on or off in a specific sequence.

When there’s an open or short circuit in any shift solenoid circuit, the TCM detects the problem, lights the MIL, and stores a code. It also stops

sending current to the faulty circuit.At the same time, the TCM goes

into failsafe operation, controlling the remaining shift solenoids to provide basic transmission operation.

Inspection ProcedureRemove the TCM from the trans-

axle and measure the solenoid resis-tances. (figure 3)

SLT, SLU, SL1, SL2, SL3, and SL4 ............................... 5.0–5.6ΩSL ................................... 11–15Ω

Check the solenoids for a short to ground; connect your meter between the each solenoid wire and the chassis ground. Resistance should be 10kΩ or higher. Below 10kΩ indicates a short to ground.

• If the solenoid resistance is okay and there’s no indication of a short to ground, you’re probably dealing with a faulty TCM.

• If the solenoid resistance is out of spec, or the resistance between the solenoid and ground is below 10kΩ, you’ll need to replace the solenoid.

...most diagnostic procedures only involve

inspecting one circuit at a time. With a basic understanding of the

system and a firm grasp on the principles

of electricity, you should have no trouble

performing accurate diagnoses and repairs.

Figure 3



Replacing the ATFThe U660E has a special ATF fill-

ing procedure to improve the accuracy of the ATF level after repairs (figures 4&5).

Because of this, the oil filler tube and oil level gauge used in convention-al automatic transmissions have been discontinued, eliminating the need to inspect the fluid level as part of routine maintenance.

That’s going to wrap it up for now. Keep your eyes open for more about the U660E as we keep these transmis-sions street smart.

Figure 4


Figure 5

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Las Vegas Convention Center, Las Vegas, Nevada

Exhibit Days: Tuesday, Nov. 2 - Friday, Nov. 5, 2010

Education Days: Monday, Nov. 1 - Friday, Nov. 5, 2010

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5219_SEMAShow_Gears.indd 1 7/2/10 9:58:54 AM


C leveland, Ohio – Transtar Industries, Inc., the premier pro-vider of world-class driveline

solutions, announces the winners of their Skin Deep promotion. Derived from Transtar’s 2010 advertising cam-paign, Commitment is More than Skin Deep, this new and unique promotion gave Transtar the opportunity to see real commitment from their customers and employees, and a whole new side of the industry.

The Commitment is More than Skin Deep campaign incorporates vari-ous advertisements featuring people with a Transtar Seal of Quality tattoo. “We always try to consider our cus-tomers when we create any advertise-ment,” said Jim Berry, Vice President of Marketing. “This campaign has real-ly hit the mark and has created quite the stir within the industry. We intend to generate even more interest throughout the year at the ATRA Powertrain Expo and upcoming seminars.”

Transtar’s Skin Deep promotion was held in the spring and consisted of two separate ‘Best Ink’ contests; one for customers and one for employees. The contests challenged both Transtar customers and employees to be creative and send in a picture with the tattoo.

The prizes included a $1,000 gift card to the Harley Davidson Store and several leather biker jackets with an embroidered Transtar logo and Seal of Quality. The grand prize winner was Jimmy Martin of AAMCO in North Attleboro, Massachusetts. Martin received a day off from work to get per-manent Transtar Seal of Quality tattoos on the palms of his hands, winning him the $1,000 gift card and a jacket.

“When I received the ‘Best Ink’ contest announcement, I knew I didn’t want to just pose in a muscle shirt – I wanted to go beyond the sticker,” said

Martin. “My shop has a great rapport with Transtar and I wanted to show my commitment to the company and to my sales representative. Many people thought I was crazy at first, but to have Ronnie’s Tattoo Studio literally tattoo the Seal of Quality and ‘Thank you Transtar’ on me was more of an honor.”

Runners-up in the ‘Best Ink’ contests included: Rickey Fuller of Brooksville Transmissions Inc., Paul Ranck of Cottman Transmission, Danny Burnsed of Danny’s One Stop Transmission Shop, Rebecca Treece of the Detroit location, Angela Peterson, branch manager of the Fort Lauderdale location and Steve Brickel of the Edison location.

One of the runners-up in the cus-tomer contest is Marvin and Laura Wilson of Advanced Transmission Inc. in Spanish Fort, Alabama. The picture they sent in of their grandson Owen posing on a motorcycle, proud to show off the Transtar Seal of Quality tattoo, won them a jacket. Marvin Wilson, also known as “Papa Dude,” demonstrated his good sportsmanlike attitude and said “There is no doubt that Mr. Martin deserves to be the Transtar grand prize winner - wow.”

The tattoo/motorcy-cle idea came at a perfect time for the Wilsons. The couple recently coordi-nated a motorcycle poker run to benefit the Ronald McDonald House, which is a place where the parents of children that are in a nearby hospital can stay at night for a reduced price or dona-tion. The ATRA-Gulf States Chapter sponsored this event.

“Owen’s mother, Amy, stayed at the Ronald McDonald House while Owen was in the hospital,” said Marvin Wilson. “Owen was born with gastros-chisis (babies born with their organs outside of the body). So, we always feel like winners when it comes to him – he is truly a miracle.”

To view the winners of the Skin Deep promotion, visit Transtar’s Facebook page at www.Facebook.com/TranstarIndustriesInc or visit www.Transtar1.com and click on the Facebook link. If customers would like to receive a temporary Transtar Seal of Quality tattoo, they should contact their Transtar representative.

Transtar Industries Inc. Announces Winners of Their “Best Ink” Promotion Jimmy Martin- AAMCO (N.

Attleboro, MA)

Jimmy Martin- AAMCO (N. Attleboro, MA)

Danny Burnsed- Danny’s One Stop Transmission Shop (Lakeland, FL)

Rickey Fuller, Brooksville Transmission’s Inc., (Quinton Fuller

–Future owner)

Paul Ranck – Cottman Transmission (Lancaster, PA)

Marvin Wilson – Advanced Transmission, Inc. Pictured, Owen, Marvin's grandson

(Spanish Fort, AL)

C M Y CM MY CY CMY K

What’s Workitng


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Company Name ATRA Account Number

Contact Person: (will receive all correspondence)

Address

City State Zip

Country

Area Code Phone No. Fax No.

Email Address

( ) - ( ) -

CONFERENCES* OTHER CATEGORIES Badges will be issued from this list. Use a separate sheet for additional registrations.*PLEASE PRINT CLEARLY (Includes Trade Show)

TO REGISTER: Call toll free 1-800-428-8489 or FAX this completed form to 805-988-6761

Complete Saturday Conference Technical Management Trade Show Tour Golf

NAME ___________________________________________________________________ £ £ £ £ £ £

NAME ___________________________________________________________________ £ £ £ £ £ £

NAME ___________________________________________________________________ £ £ £ £ £ £

NAME ___________________________________________________________________ £ £ £ £ £ £

NAME ___________________________________________________________________ £ £ £ £ £ £

Before Aug. 30th ALL

REGISTRATION FEES Qty Member Non Mem ON-SITE SUBTOTAL

Complete Conference Registrant* _____ $ 345 $ 445 $ 495 $____________

Technical or Management Conference* _____ 295 395 445 $____________

Trade Show _____ 10 10 30 $____________

“Discover San Antonio” Tour (Saturday, September 11th) _____ 79 79 100 $____________

Golf Tournament (Thursday, September 9th) _____ 125 125 125 $____________

Certification Testing (Sunday, September 12th) FREE _____ - - - - $____________

TOTAL $____________

PAYMENT INFORMATION* Check enclosed payable and mail to: ATRA, 2400 Latigo Avenue, Oxnard, CA 93030 Check # ___________________

Charge to: * MasterCard * Visa * AMEX * Discover

Card Number ___________________________________________________Expiration Date Security Code

Print Name on Card _________________________________________________________ Signature __________________________________________

Discount for current ATRA Members only. Join today and enjoy the member discount right away!

I do not wish to receive any advertising or promotional material from Exhibitors.

*Conference Registrants may receive Trade Show Passes for spouse and/or children by contacting ATRA Registration at 1-800-428-8489.


Before Aug. 30th ALL

REGISTRATION FEES Qty Member Non Mem ON-SITE SUBTOTAL

Complete Conference Registrant* _____ $ 345 $ 445 $ 495 $____________

Technical or Management Conference* _____ 295 395 445 $____________

Trade Show _____ 10 10 30 $____________

“Discover San Antonio” Tour (Saturday, September 11th) _____ 79 79 100 $____________

Golf Tournament (Thursday, September 9th) _____ 125 125 125 $____________

Certification Testing (Sunday, September 12th) FREE _____ - - - - $____________

TOTAL $____________


In the July issue we looked at the first month’s performance of the atra.com website, specifically

designed for reaching consumers. We used several methods for tracking the traffic to the site including Google Analytics, Alexa, and the built-in reporting feature of the site itself. A lot of the traffic ATRA receives is a result of press releases and other publications directing readers to the site. The cover-age has been fantastic and the site has been receiving more traffic than any other transmission-related organization or group in the industry.

But it gets better than that. The new atra.com site has a local search

feature called "ATRA Local Search." It’s similar to the Shop Finder in terms of locating ATRA member shops based on search criteria, however, the ATRA Local Search feature is stand alone; working directly with the search engines rather than through the ATRA site. This feature provides local search results when a consumer enters a city as part of their search query; such as “transmission repair Ventura”. The search engines then return the results based on that search (Figure 1). Or, if someone types “automatic transmission Flint MI” they’ll get this result: #1 on Google right under the sponsored links (Figure 2). When someone clicks on

that search result it goes directly to the Shop Finder page that lists ATRA mem-ber shops in or near that city. There are over 300 USA and Canadian cities built into the feature (with more to come) that trigger these results.

This feature began to get picked up by the search engines toward the end of May and the increased exposure caused an explosion of traffic to ATRA mem-bers and their web sites for the month of June. The cities with less popula-tion are currently ranking higher since there’s less competition and the results for a given city vary from one search engine to another.

by Dennis Maddenmembers.atra.com

www.atra.com

MEMBERSHIP MATTERS

ATRA's Local Search –Bringing Real Performance

Figure 1


Figure 3

For June, the average viewings of ATRA members’ contact information was 124 per member and the total visits to ATRA member web sites was over 62,000, compared to just over 9,200 for May. Figure 3 shows a chart of weekly clicks to ATRA member websites since the site launched.

As you can see, the traffic has really increased as the local search feature has taken hold. This gives you enormous exposure as an ATRA mem-ber. Your Web site has the potential to be a powerful marketing tool that drives people to your shop – especially if it is receiving large amounts of traf-fic from ATRA’s site. By linking your site to ATRA’s Shop Finder, you will get one of the most respected names in transmission repair behind you for even more credibility, and your sales will see an increase directly related to increased visits to your site. Don't have a website? ATRA offers websites to it's Members for only $10 per month (plus a first-time set up fee).

ATRA has become a valuable resource for consumers to find informa-

tion about their transmission problems and to find repu-table shops. The Shop Finder and ATRA Local Search fea-tures are more than a simple list of transmission shops in or near a city, they’re tied into ATRA; a name more and more consumers see as a sign of trust.

...the total visits to ATRA member web

sites was over 62,000, compared to just

over 9,200 for May.

Figure 2

Without Customers...Where are you?

ATRA helps you...

(866) GO-4-ATRA • (866) 464-2872www.atra.com/join

&Get ‘em in the DoorNationwide Warranty Program

Certification DesignationPre-designed Advertisements

Member Directory on www.atra.comCommercial Footage

Professional Website Design

Get ‘em out the DoorTechnical SeminarsTechnical HotLine

ATRA’s Tech Knowledge BaseTesting & Certification

ATRA’s Powertrain ExpoTechnical Training

Apply for ATRA Membership Today

members.atra.com


ATRA Groups Now Interactive Online

ATRA’s member web site was implemented to further benefit ATRA members and create a more user-friend-ly environment. The latest extension of that support is our “What’s Working” group function – a fantastic tool for many shop owners and managers that is already regularly viewed by its 350 active members.

The member Web site allows mem-bers to sign in, manage their account, renew membership, order warranty sup-plies and have access to all of ATRA’s group discussions – including individu-al groups based on location, groups for members with Web sites and the new “What’s Working” group.

All active members are automati-cally a part of the “What’s Working” management group – there is no need to join. To join and manage all other indi-vidual groups, visit the member Web site. There is no fee associated with joining the groups – it’s all included with your ATRA membership.

The “What’s Working” tool allows group members to:

• Search posts• Edit their posts• Delete their posts• Attach a file or image to

your message or group photo gallery

• Paste an embedded code from YouTube or other video sharing service

• Allow or disallow comments on a post

• Opt in or out of receiving various email notifications

FeaturesThe group discussion forum has

received several user-friendly enhance-ments to further support member needs.

After joining a group discussion, you will be able to see past posts on a vari-ety of topics made by other participants. This allows you to review and comment

Figure 1: Where to Request Access to the “What’s Working” Group

Figure 2: “What’s Working” Group Home Page


on any existing threads, even ones that were posted before you joined that group.

The group discussions are not only good for providing and receiving indus-try insight, but for meeting and learning more about individual posters. While reviewing a post in a group, you can click on the name of the person who posted the topic and it will take you to their profile page. For example, if someone posts how to run a successful business in a small town, you can visit their profile to learn more about them, send them a message or even visit their Web site. If that member is currently logged on to the site, as well, you can start a chat session with the member.

For added convenience, one of the premier features is the ability to manage your own email subscriptions. Members can now decide which email notifications you want to receive from the group, such as new posts, the join-ing of new members, updated profiles, uploaded photos and event updates. If you prefer to not receive any email

notifications and just check the site yourself, you have that option. For important news, you can send a mes-sage to all members of your group.

Of course, you can unsubscribe from any group at any time, with-out having to contact ATRA to do so. Should you decide to become a part of the group discussion again, you can request to join just as easily.

Better BusinessThe new “What’s Working” group

brings all the great benefits of the previous Management group forum while adding many of the familiar func-tions of such social networking sites as Facebook, increasing connectivity and convenience.

You now have control over what information you want to receive and how you want to receive it. This is a true enhancement in ATRA mem-ber communication and better business practices.

How to Join a GroupOnce you’ve become an ATRA

member, you are automatically given access to the “What’s Working” group forum. To join other groups, you can make a simple request through the ATRA member Web site.

Once you’re connected to the group, you may begin to make posts and share insights on topics relating to your business with other members that share the same experiences. This kind of interaction – at whatever level you choose to participate – can only work to spread valuable industry knowledge and experience between ATRA mem-bers.

ATRA NEWS

Figure 3: My Subscriptions

Last month there were over 60,000 visits to ATRA member websites through ATRA’s Shop Finder

Was your site one of them?

(866) GO-4-ATRA or (866) 464-2872 • http://members.atra.com/join

Become a Member and Get Customers


Sonnax Introduces Lubricating Pressure Control Valve for Mercedes 722.6

The Mercedes 722.6 can experi-ence severe wear at the lubricating pres-sure control valve. This often causes delayed engagements or complaints of poor performance and higher-than-nor-mal stall speeds.

The Sonnax Lubricating Pressure Control Valve

Kit 68942-14K will reestablish converter

and lube oil pressure

c o n t r o l . This kit offers increased durability, calibrated pressure control, and will prevent converter overheating due to low pressure or converter damage due to excess pressure.

For more information, visit Sonnax on line at www.sonnax.com.

Alto Products Announces TS 16949:2009 Certification

Alto is pleased to announce its TS 16949:2009 certification. TS 16949:2009 is an international quality standard required of most Tier 1 suppli-ers to on-highway vehicles. Alto is also ISO 9001:2008 and ISO 14001:2004 certified.

“TS is required to do business with many OE organizations,” said Bill Busch, COO of Alto Products. “As our OE footprint grew and we became a supplier to companies such as Volvo and Ford, this became a necessity.”

Alto Products is the oldest and largest independently owned-and-oper-ated clutch manufacturer in the world. Alto has manufactured over a billion clutches over the last 50 years for auto-motive, high performance, heavy duty, marine, and motorcycle applications.

Corporate headquarters are located in Alabama and the company operates three US manufacturing plants, four North American distribution facilities,

and international offices in Mexico, The Netherlands, UAE, India, China, Taiwan and Australia.

For more information please visit www.altoUSA.com.

New Partnership Brings Solenoid Took Kit to Seal Aftermarket Products

Cottingham Engineering of Kettering Northants, England and Seal Aftermarket Products of Pembroke Park, Florida announced their exclu-sive partnership agreement for North American distribution of Cottingham’s #1 Aisin SL Solenoid Tool Set.

Alan Smith, managing director of Cottingham Engineering, is pleased with the opportunities that this partner-ship will bring to both companies.

Wendy Ritz, international sales manager of Seal Aftermarket Products, said, “The exclusive distribution agree-ment will afford Cottingham time to develop more solenoid disassemble and reassemble tools, test plates, and other needed rebuilder tools. Seal Aftermarket Products and their Toledo Trans Kit brand have always been known for aftermarket fixes; the part-nership between Cottingham and Seal Aftermarket Products strengthens that commitment to engineering entrepre-neurship.”

Because of this partnership, Seal Aftermarket Products is pleased to introduce Cottingham’s #1 Aisin SL Solenoid Tool Set for disassembling and repairing transmission solenoids.

The new kit comes complete with its own custom carrying case.

The solenoid tool set allows you to quickly disassemble and assemble sole-noids for the following 5- and 6-speed units:

• AW55-50• TF60 (09G, 09M, 09K)• TR60 (09D)• TF80 (AF40-6)And this kit is exclusively avail-

able from Seal Aftermarket Products.For more information,

call 1-800-582-2760, or email [email protected].

Rancho Performance Exclusive Distributor of PBS RD-4 Transaxle

The highly sought after PBS RD-4 is now available exclusively through Rancho Performance Transaxles. Designed as a cost effective, high per-formance transaxle for off-road and sand cars, each RD-4 is built to order.

The RD-4’s unique H-pattern cable shifter makes them easily adapted to mid- or rear-engine cars, simply by selecting the appropriate cable length and routing.

The RD-4 main case is precision cast and machined from aircraft qual-ity A356 aluminum. Shaft centers are

POWERTRAIN INDUSTRY NEWSGEARS does not endorse new products but makes this new information available to readers. If you have a new product, please email the press release information with applicable digital photo or drawing to [email protected] or send by mail to GEARS, 2400 Latigo Avenue, Oxnard, CA 93030.

#1 Aisin SL Solenoid Tool SetComplete with custom carrying case.

SAVE TIME and Money

Quickly disassemble & assemble solenoids For the following 5 and 6 speed units:

AW55‐50 TF60 (09G, 09M, 09K)

TR60 (09D) TF80 (AF40‐6)

Exclusively Available from S.A.P. Call 1‐800‐582‐2760 * Fax 954‐364‐2401 Email SAPCustomerservice@TTK‐Bryco.com #35199

Seal Aftermarket Products LLC

Seal Aftermarket Products LLC 2315 S.W. 32nd Ave Pembroke Park, FL 33023 Ph. 954-364-2400 Fax 954-364-2401

Partnership Announcement

Alan Smith and Wendy Ritz Cottingham Engineering of Kettering Northants, England and Seal Aftermarket Products of Pembroke Park, Florida announce their exclusive partnership agreement for North American distribution of Cottingham’s #1 Aisin SL Solenoid Tool Set. Alan Smith, Managing Director of Cottingham Engineering is pleased with the opportunities that this partnership will bring to both companies. Wendy Ritz, International Sales Manager of Seal Aftermarket Products states that the exclusive distribution agreement will afford Cottingham the time to develop more solenoid disassemble and reassemble tools, test plates, as well as other needed rebuilder tools. Seal Aftermarket Products and their Toledo Trans Kit brand has always been known for ‘aftermarket fixes’; the partnership between Cottingham and Seal Aftermarket Products strengthens that commitment to engineering entrepreneurship.


POWER INDUSTRY NEWS85mm apart, allowing for substantially larger bearings and gear sets, and the rugged reverse gears feature a larger diameter, 3-piece design.

Output flanges are available for 930 and 934/935 CV joints with heavy duty Dana 60 differential. Gear place-ment remains standard as are the dura-ble 9310 chromoly steel, 6-lug dog rings. 18-spline input shaft is machined from 300 M steel.

Internal shifter mechanism incor-porates reverse lockout, which prevents selecting both reverse and a forward gears simultaneously. Putting the gear-box in neutral with the 4-speed selector allows you to engage reverse with the separate lever. When you disengage reverse, you can engage the forward gears in any order.

Rancho supplies new RD-4s with a shift handle and a separate, cable-operated, reverse shift lever assem-bly. As applications vary, cables are not included.

Rancho’s PBS RD-4 provides exceptional strength, reliability and durability for the all-around dirt/sand enthusiast, and does it for just $7995!

For complete details and order-ing information, call 714-680-6737. Be sure to visit the Rancho Site at www.ranchotransaxles.com

Smart Blend Introduces New Power Steering Fluid

You already know the Smart Blend name for their transmission additives. Now they’re offering One Formula Multi-Vehicle Power Steering Fluid; a new power steering fluid suitable for use in all power steering services and fluid exchanges.

The new fluid includes advanced Synteum® technology. It combines exceptional low temperature fluidity

with outstanding shear stability to meet and exceed the most stringent perfor-mance OEM requirements. It also helps prevent corrosion, wear and oxidation.

Smart Blend Synthetics’ Multi-Vehicle Power Steering Fluid is spe-cially formulated to be used in all power steering services and exchanges requiring regular power steering fluid or specialty high performance lubricat-ing oils for fluids, such as CHF+.

For more information, visit Smart Blend on line at www.smartblend.com, or call, toll free, 1-888-422-9099.

Sun Coast Diesel Builds Transmission Rebuild Kits that You Know Will Work

Sun Coast Diesel has just announced its new line of transmission rebuild kits.

Each of their rebuild kits, or “pacs” as they call them, is prototyped, engi-neered and tested with high-horsepow-er trucks before releasing them. They manufacture many key components in-house so they can ensure the highest quality parts.

Sun Coast’s pacs come with many options like hydraulics, gaskets, filters, and upgrades. And they offer tech sup-port from the guys who help design, manufacture, and install these pacs on a daily basis.

Sun Coast pacs are identifiable with the vehicle manufacturer; “GMax pac” is the GM/Allison line, “M3GA pac” is the Dodge line, and “Iron pac” is the Ford line.

Their specialty transmissions/parts are 4L80E, Allison 1000/2000, 47RH, 47RE, 48RE, 68RFE, E4OD, 4R100, 5R110 and they’re working on the 6R140 now.

Sun Coast also designs and CNC machines their own converter parts, like custom billet stators and 3-disk converter covers, to match the extra horsepower your customers will add to their trucks. For more information, visit www.suncoastdiesel.com or call

(877)-742-8213.

Transforce Industries Now Offers Rear Cases for NV Transfer Cases

Transforce Industries now has remanufactured rear cases available for New Venture 246, 261, 263XHD trans-fer cases.

These cases are expertly welded and machined, and include a heavy duty steel bumper already installed. The snap ring groove is brought back to new specifications with a steel shim and steel bearing retainer.

For more information, call (902) 860-1474, or send an email to [email protected].

Seal Aftermarket Products Announces Corporate Organizational Changes

Seal Aftermarket Products has made the following changes to its cor-porate structure:

Chris MacLeod is the domestic sales manager for Seal Aftermarket Products. Chris is a twenty-four year veteran in the automotive OE market, formerly with Parker Hannifin. His expertise in automotive products and systems, both in sales and market-ing, makes Chris an asset to the Seal Aftermarket Products management team. Chris will work from his home in Tampa, Florida and can be reached at (810) 444-5515 or email at [email protected].

Chip Carlson, Francisco Lopez, and Marty Novil are three sales repre-sentatives who will focus exclusively on the Mexican market.

Chip has worked in the automotive industry for more than 15 years. Prior to founding Cima International, Chip was employed at ROL Manufacturing and Freudenberg NOK. Chip brings his excellent project management skills to the Seal Aftermarket Products team. Chip can be reached at 440-398-0108

FAX: 281-631-0460 www.smartblend.com •

For product pricing or more information about SMART BLEND Products

Call: 1-888-422-9099 or Email: [email protected]

NEW PRODUCT RELEASE

MULTI-VEHICLEPower Steering Fluid

PT#14005

ŸFOR USE IN POWER STEERING SYSTEMS

ŸSuperior Performance in Power Steering Systems

ŸAdvanced Synthetic FormulaŸOutstanding High & Low Temperature

PerformanceŸExcellent Shear StabilityŸHelps Prevent Corrosion, Wear &

Oxidation

ALL

Smart Blend Synthetics introduces One Formula Multi-Vehicle Power Steering Fluid in a translucent 64 oz. bottle. NEW Smart Blend Synthetics’ Multi-Vehicle Power Steering Fluid with advanced

Technology combines exceptional low temperature fluidity with outstanding shear stability to meet and exceed the most stringent performance requirements of OEMs. Smart Blend Synthetics’ Multi-Vehicle Power Steering Fluid is a specially formulated fluid, to be used in power steering services/exchanges requiring regular power steering fluid or specialty high performance lubricating oils or fluids, such as: CHF+.

SYNTEUM®

ALL

For Use in Power Steering Services and Exchanges.ALL

Smart Blend Synthetics Multi-Vehicle Power SteeringFluid benefits include:

SYNTHETIC


or email at [email protected].

Francisco has worked in the auto-motive industry in operations and sales for more than 17 years. Francisco’s expertise in organizational operations is an asset for Seal Aftermarket Products and our customers. Francisco lives in Guadalajara and can be reached at 52 (33) 3666-2936 or email at [email protected].

Marty has worked for over thirty years in sealing systems Technology. Most recently the director of tech-nology of sealing products for ROL Manufacturing, Marty holds several patents in design engineering. Marty is ready to help Seal Aftermarket Products and their customers design new after-market fixes. Marty can be reached by email [email protected].

J.P. Transmission Salvage is Now J.P. Transmission Recycling

J.P. Transmission Salvage Inc. has changed its name to J.P. Transmission Recycling, and they’ve moved to a new facility at 1220 Dowdy Ferry Road in Hutchins, Texas.

The reason? They outgrew their Wilmer Texas facility, which was about 2.5 acres, including offices, warehouse, breakdown assembly, and receiving area. Their new facility sits on 7.26 acres, including 50,000 sq. ft. of office, warehouse, shop space, and outdoor storage.

The company will continue to buy automatic transmission cores, along with standards, torque converters, cata-lytic converters, and various recyclable metals.

They plan to continue to grow in the sale and distribution of used hard parts and cores, selling throughout the United States and Puerto Rico, Mexico, Central and South America, Canada, and parts of Europe and the Middle East.

J.P. Transmission Recycling is very proud of its history: They started in a small, 3000 sq. ft. facility in Wilmer Texas in 1979; a far cry from its present 50,000 sq. ft. plant!

They’re now in the process of updating their web site to include the new facility and its additional capabili-ties; visit them on line at www.jptrans-mission.com.

New Kit Is Tough on Leaks, Easy on the Budget!

Tracer P r o d u c t s has unveil-ed the ex-t r e m e l y affordable Tracerline® T P - 8 6 2 7 EZ-Ject™ Leak Detection Kit that saves technicians time and trouble pin-pointing leaks in air conditioning and fluid systems. The heart of the kit is the OPTI-Lite™ high-intensity, 6-LED, blue light flashlight that’s so powerful, it makes even the smallest leaks clearly visible.

Another important component is the EZ-Ject™ multi-dose dye injector, a fast and easy way to add fluorescent dye to multiple A/C systems. Just turn the handle to inject the exact amount of dye into the system. There’s no mess to clean up!

The kit contains a 0.5 oz. univer-sal A/C dye cartridge that services up to 14 vehicles. Also included are a 1 oz bottle of Dye-Lite™ All-In-One™ dye for oil, fuel, ATF, power steering, and hydraulic systems; a 1 oz bottle of Dye-Lite™ coolant dye; an 8 oz spray bottle of GLO-AWAY™ dye cleaner; and fluorescence-enhancing glasses. All are con-veniently stored in a sturdy plas-tic carrying case.

All Tracerline® universal/POE dyes have been laboratory tested and proven safe for use in

hybrid vehicles.For more information about the

TP-8627 EZ-Ject™ Leak Detection Kit, call toll-free 1-800-641-1133. Outside the United States and Canada call 516-333-1254. Visit them on line at www.tracerline.com.

Zf Services Opens Distribution Center Expansion In Vernon Hills, Ill

Vernon Hills, Ill. – ZF Services, the strategic aftermarket business unit of ZF Friedrichshafen AG, recently celebrated the grand opening of its expanded distribution center. The cen-ter was enlarged by nearly 81 percent to improve efficiencies and customer service.

“With our centralized location, great people, quality products and com-mitment to excellence, I know we will exceed our customers’ expectations,” said Tim Corcoran, President and COO of ZF Services North America, who dedicated the expanded facility with about 300 colleagues. “Having all of our competencies under one roof will allow our organization to be extreme-ly flexible in meeting our customers’ needs.”

ZF Services broke ground on the expansion in May 2009, about a year and a half after the merger of ZF Sales & Service NA, LLC and ZF Trading NA, LLC was announced.

Construction was completed last October, followed by two months of facility preparation and three months of transferring more than 255 truckloads of products from an Ohio distribution facility.

The 129,000-square-foot expan-sion brings the total size of ZF Services’ Vernon Hills, Ill. aftermarket remanu-facturing, administration and distribu-tion center to 289,000 square feet. The facility originally opened in 1993.



Organizational Announcements

Chris MacLeod Chip Carlson Francisco Lopez Marty Novil

Chris MacLeod is the Domestic Sales Manager for Seal Aftermarket Products. Chris is a twenty-four year veteran of the Automotive OE market formerly with Parker Hannifin. His expertise in automotive products and systems both in sales and marketing makes Chris an asset to the Seal Aftermarket Products management team. Chris will work from his home in Tampa, Florida and can be reached at (810) 444-5515 or email at [email protected].

Chip Carlson is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively on Mexico. Chip has worked in the Automotive Industry both OE and Aftermarket for more than 15 years. Prior to founding Cima International, Chip was employed at ROL Manufacturing, and Freudenberg NOK, Chip brings his excellent project management skills to the Seal Aftermarket Products team. Chip can be reached at 440-398-0108 or email at [email protected].

Francisco Lopez is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively in the Mexico Market. Francisco has worked in the Automotive Industry in operations and in sales for more than 17 years. Francisco’s expertise in organizational operations is an asset for Seal Aftermarket Products and our customers. Francisco lives in Guadalajara and can be reached at 52 (33) 3666-2936 or email at [email protected].

Marty Novil is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively in the Mexico Market.Marty has worked for over thirty years in Sealing Systems Technology. Most recently, the Director of Technology of Sealing Products for ROL Manufacturing, Marty holds several patents in design engineering. Marty is ready to help Seal Aftermarket Products and their customers design new aftermarket fixes. Marty can be reached by email [email protected]..



Organizational Announcements

Chris MacLeod Chip Carlson Francisco Lopez Marty Novil

Chris MacLeod is the Domestic Sales Manager for Seal Aftermarket Products. Chris is a twenty-four year veteran of the Automotive OE market formerly with Parker Hannifin. His expertise in automotive products and systems both in sales and marketing makes Chris an asset to the Seal Aftermarket Products management team. Chris will work from his home in Tampa, Florida and can be reached at (810) 444-5515 or email at [email protected].

Chip Carlson is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively on Mexico. Chip has worked in the Automotive Industry both OE and Aftermarket for more than 15 years. Prior to founding Cima International, Chip was employed at ROL Manufacturing, and Freudenberg NOK, Chip brings his excellent project management skills to the Seal Aftermarket Products team. Chip can be reached at 440-398-0108 or email at [email protected].

Francisco Lopez is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively in the Mexico Market. Francisco has worked in the Automotive Industry in operations and in sales for more than 17 years. Francisco’s expertise in organizational operations is an asset for Seal Aftermarket Products and our customers. Francisco lives in Guadalajara and can be reached at 52 (33) 3666-2936 or email at [email protected].

Marty Novil is one of three Sales Representatives for Seal Aftermarket Products that will focus exclusively in the Mexico Market.Marty has worked for over thirty years in Sealing Systems Technology. Most recently, the Director of Technology of Sealing Products for ROL Manufacturing, Marty holds several patents in design engineering. Marty is ready to help Seal Aftermarket Products and their customers design new aftermarket fixes. Marty can be reached by email [email protected]..

© 2009 ATRA. All Rights Reseerved.

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Clutch Op

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Scan Toool Acronyms .................

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....................102

Test Toools ........................

........................

................106

Code DDescriptions.........................

.........................

...108

Modulee and Connectors ..........................

...................110

Power and Ground Circuits.........................

..............111

Rangee Sensor.......................

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............112

Sensoor Circuits.........................

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.......113

Undeerstanding Clutch Volumme Inndex ........................1

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....................116

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........117

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.......................1

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Oil Pump Valve Descriptionn ........................

.............120

Uppper Valve Body ..........................

........................

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.........................

....123

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..................124

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....125

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.........126

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131

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........................

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..............133

Overhaul Tips ..........................

........................

.........134

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.........................

......13

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.................13

Solenoid, Pressure SSwittches annd Valvve Body...........1

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ATRA All Righhts Reserveded © 2010

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Call Now(800) 428-8489


ERIKSSON INDUSTRIES

•1 YEAR UNLIMITED MILE WTY•

1-800-388-4418Division of Wentworth Engineering

Authorized Parts Distributor

•Remanufactured Units * DYNO TESTED*•5HP30, 5HP24, 5HP19, 5HP18, 4HP24, 4HP22, 4HP18, 4HP14•Specializing in SAAB 900/9000 5SP, as well as T-37 A/T

• Hard Parts: NEW / USED / REMANUFACTURED

Soft Parts / Friction Kits / Steel Kits / Repair Manuals

• Lifetime Fluids / Rebuild Kits / Valvebody Kits

1-800-388-4418Fax: (860) 395-0047

www.erikssonindustries.com146B Elm St., Old Saybrook, CT 06475

**COMPUTERS**Transmission Control Module

E C M & T C MMitsubishi-Honda-Hyundai-GEOKia-Mazda-Nissan-Suzuki-Toyota

BOSCH ECMGM - Ford - Chrysler - Dodge

Next Day Air Shipping AvailableOne Year Warranty

Best Customer Service!Ford *GM * Chrysler off vehicle ECM reprogramming available

8 8 8 - 2 1 7 - 4 0 7 2Autocomp Technologies, Inc.8515 N. Freeway, Houston, Texas www.g-tec.comwww.g-tec.com

Heated Cooler Line Flusher

Transmission Dyno/CV Tester

800-725-6499417-725-6400

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Quality Parts-Fair Prices-Excellent Service

SHOPPER CLASSIFIED ADS


SHOPPER CLASSIFIED ADSGEARS Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders. For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call (805) 604-2000.

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Valve Body KitsRatioTek™

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•COMPLETE UNITS OR TRANSFER CASE PARTS•NEW AND REBUILT TRANSMISSIONS•OVER 1,000 AXLES IN STOCK•REBUILD KITS IN STOCK•UPS DAILY•DAILY DELIVERIES TO YOUR DOOR•S•STANDARD, EXTENDED & LIFETIME WARRANTY OPTIONS

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SHOPPER CLASSIFIED ADSGEARS Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders. For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call (805) 604-2000.

Quality Remanufactured Torque Converters

Expect the Best!

800.727.4461

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Leading The Industry Since 1978

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This cd contains over 1200 pages of Gears technical articles, there are 4 years, 260 articles

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For our Canadian Subscribers

Some of the 800- toll free numbers listed in the shopper ad section do not work In Canada. Therefore, as a service to you we have listed direct line phone numbers to our shopper

advertisers:

www.atra.com

A&REDS Transmission Partshas multiple locations

Eriksson Industries (860) 388-4418

Transmission Exchange Co. (503) 284-0768

Autocomp Technologies (713) 697-5511

Precision of New Hampton Inc (641) 394-5955

Lory Transmission Parts (305) 642-4621

Miami Transmission Kits (305) 885-7355

ART Auto Sport Unlimited Remanufactured Transmissions

(616) 748-5725

Weller Auto TrucksHas many different shop locations

Instaclean (928) 680-4445

Silver Star Transmission (405) 330-9300

Trans-Pac Motor Parts (310) 637-9156

Transfer Case Express has multiple locations


BUSINESS FOR SALE: Unique transmission shop located in the heart of Montana for sale. This pristine shop is 40 by 60 foot, features 2 Rotory hoists and much more equipment. Also in-cluded, a 2 story, 2 bath house with a full unfinished basement. The backyard has a natural spring with a pond stock with fresh trout and 5 acres of prime Montana land. This property is 7 miles outside of Lewistown, Montana. Call (406) 538-9085 Serious inquires only please.

BUSINESS FOR SALE: Califor-nia – You need to take a look at this one! 40 years of excellent business transmission & general automotive service. Same great location, central California, this is not your ordinary shop. Large building with latest equipment, owner ready to retire. Contact (209) 602-7250. ATRA Mbr

HELP WANTED: Transmission Technical Director - National re-manufacturer of transmissions seeks an experienced technical director to oversee and direct quality procedures, remanufac-turing specifications and pro-vide “hands on” training to re-builders. Must have a minimum

of 10 years experience, have experience in GM, Ford, and Chrysler transmissions, posses excellent communication skills, both written and oral, be detail oriented and have strong lead-ership skills. Our company of-fers excellent working environ-ment with modern equipment. Pay is based on experience and we offer full health, life, dental benefits and more. Please email your resume´ to [email protected], it will be held in the strictest confidence.

HELP WANTED: Indiana - Ex-perienced transmission rebuild-er needed. Must be able to build front and rear wheel drive trans-missions, manual and automatic transfer cases, foreign and do-mestic. Our shop is clean with the latest diagnostic equipment. Opened Monday through Friday, includes insurance, uniforms, paid vacations and holidays. Lo-cated in Osceola, Indiana con-tact Dave at (574) 651-5000. ATRA Mbr

HELP WANTED: Alto Products Corp., R&D Specialist - Join the Alto research and development team. Position requires at least 3 years of R & R, Rebuilding,

SHOPPER CLASSIFIEDGEARS classified advertising cost $95.00 for up to 50 words for a one time insertion. ATRA members are eligible to receive up to three (3) FREE classified advertisements in GEARS annually (per 9 issues). Members wishing to place ads once their three FREE ads have been placed may do so at the cost listed above. Ads exceeding the maximum word count will cost $1.50 for each additional word (not including phone number and address).

August 2010

#1 Aisin SL Solenoid Tool SetComplete with custom carrying case.

SAVE TIME and Money

Quickly disassemble & assemble solenoids For the following 5 and 6 speed units:

AW55‐50 TF60 (09G, 09M, 09K)

TR60 (09D) TF80 (AF40‐6)

Exclusively Available from S.A.P. Call 1‐800‐582‐2760 * Fax 954‐364‐2401 Email SAPCustomerservice@TTK‐Bryco.com #35199


and Diagnostic experience. Excellent commu-nication and technical skills require. Must be proficient in MS Office applications, AutoCAD skills are preferred. Technical Certificate or As-sociates degree preferred. Apply for this position at http://altousajobs.com/index/app. ATRA Mbr

HELP WANTED: High volume shop in Sacra-mento, California – Seeking a builder with ex-tensive knowledge and capability to build and diagnose the latest model American, Japanese and European units. (i.e. 5R110W, AW55-50, JF06E, etc.) Top pay for the right builder. Great environment to work in with paid holidays. Only the best wanted, will help pay relocating expens-es. Call West Coast Transmission, Inc. at (916) 348-3962 or fax resume to: (916) 348-3967 or email: [email protected]. ATRA Mbr

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2010

ADVERTISERSName Page Name Page

AA Midwest .......................................................................... 27 www.aaeq.netAlto Products Corp. ............................................................. 27 www.altousa.comArrow Uniform ..................................................................... 26 www.arrowuniform.comATRA .......................................................................50, 52, 56 members.atra.comCertified Transmission ........................................................... 9 www.certifiedtransmissions.comETE Reman ......................................................................... 15 www.enginetrans.comEVT Parts ............................................................................ 19 www.evtparts.comExedy Globalparts Corporation ........................................... 35 www.exedyusa.comFirst National Merchant Solutions ....................................... 30 www.fnms.comG-Cor Automotive Corp ....................................................... 30 www.transmisionshardparts.comHeffernan Group .................................................................. 32 www.heffgroup.comInternational Torque Converters .......................................... 33Jasper Engines & Transmissions ...................................... IBC www.jasperengines.comLife Automotive Products Inc. ........................................21, 26 www.smartblend.comLubegard® By International Lubricants, Inc. ................... OBC www.lubegard.comPrecision European Inc. ...................................................... 63 www.peius.com

Precision International ......................................................... 29 www.transmissionkits.comRaybestos Powertrain ........................................................... 5 www.raybestospowertrain.comSeal Aftermarket Products- Parker Hannifin Corporation ............................................ 13 www.parker.comSEMA...................................................................................41 www.sema.orgSlauson Transmission Parts ................................................ 31 www.slauson.comSonnax Industries .............................................................. IFC www.sonnax.comSuperFlow Technologies Group .......................................... 32 www.superflow.comSuperior Transmission Parts .....................................7, 37, 39 www.superior-transmission.comTCI Automotive .................................................................... 33 www.tciauto.comTransmission Exchange Co. ............................................... 37 www.txchange.comTransmission Specialties ..................................................... 17 www.transmission-specialties.comTranstar Industries, Inc. .................................................23, 43 www.transtarindustries.comTransTec By CORTECO ...................................................... 25 www.transtec.comWhatever It Takes Transmission Parts, Inc. .......................... 3 www.wittrans.com

2010

CALENDARCALENDAR

8/7/10 Los Angeles, CA9/9/10 – 9/12 ATRA's Powertrain Expo, San Antonio, TX9/25/10 Chicago, IL10/9/10 Portland, OR10/16/10 New York, NY

ATRA Technical Seminar Schedule

jasper ibc.indd IBC2jasper ibc.indd IBC2 1/8/09 9:03:00 AM1/8/09 9:03:00 AM

<< /ASCII85EncodePages false /AutoPositionEPSFiles true /AutoRotatePages /None /Binding /Left /CalGrayProfile (Gray Gamma 2.2) /CalRGBProfile (sRGB IEC61966-2.1) /CalCMYKProfile (U.S. Web Coated \050SWOP\051 v2) /sRGBProfile (sRGB IEC61966-2.1) /CannotEmbedFontPolicy /Error /CompatibilityLevel 1.3 /CompressPages false /ConvertImagesToIndexed true /CreateJobTicket false /DefaultRenderingIntent /Default /DetectBlends true /ColorConversionStrategy /LeaveColorUnchanged /DoThumbnails false /EmbedAllFonts true /EmitDSCWarnings false /EndPage -1 /ImageMemory 524288 /LockDistillerParams true /MaxSubsetPct 100 /Optimize false /OPM 1 /ParseDSCComments true /ParseDSCCommentsForDocInfo false /PreserveCopyPage true /PreserveEPSInfo false /PreserveHalftoneInfo true /PreserveOPIComments false /PreserveOverprintSettings true /StartPage 1 /SubsetFonts true /TransferFunctionInfo /Preserve /UCRandBGInfo /Preserve /UsePrologue false /ColorSettingsFile (Color Management Off) /AlwaysEmbed [ true ] /NeverEmbed [ true ] /AntiAliasColorImages false /DownsampleColorImages true /ColorImageDownsampleType /Bicubic /ColorImageResolution 300 /ColorImageDepth 8 /ColorImageDownsampleThreshold 1.10000 /EncodeColorImages true /ColorImageFilter /FlateEncode /AutoFilterColorImages false /AntiAliasGrayImages false /DownsampleGrayImages true /GrayImageDownsampleType /Bicubic /GrayImageResolution 300 /GrayImageDepth 8 /GrayImageDownsampleThreshold 1.10000 /EncodeGrayImages true /GrayImageFilter /FlateEncode /AutoFilterGrayImages false /AntiAliasMonoImages false /DownsampleMonoImages false /MonoImageDownsampleType /Bicubic /MonoImageResolution 1200 /MonoImageDepth -1 /MonoImageDownsampleThreshold 1.50000 /EncodeMonoImages true /MonoImageFilter /CCITTFaxEncode /MonoImageDict << /K -1 >>>> setdistillerparams<< /HWResolution [2400 2400] /PageSize [612.000 792.000]>> setpagedevice

Synapse Prepare Typical Printer Inc:CMYK Composite QuarkXPressª Settings: Incl_NoOv_Mrks_CompUser may modify QuarkXPressª settings prior to sendingInDesignª Print Style: Incl_NoOv_Mrks_CompDistiller Job Options: Creo PDF Pages.joboptionsPitStop Profile: W_Images_CMYK.pppPitStop Actions: Convert Color to CMYK.eal SynapseLogo.ealUser can add info annotations into resulting PDFDistiller annotations will be added into resulting PDFJob Info annotations will be added into resulting PDFDirective annotations will be added into resulting PDF�

Job Name: Synapse Prepare JobJob Number: V14Proof Due: Thu, Jul 4, 2002Final Due: Thu, Aug 29, 2002Company: Synapse Prepare Inc.Contact: ToddAddress: 18 PDF LaneCity: AlbertvilleState: BC Zip: Country: Office Phone: 555-555-1212Email: [email protected]: Please call if you have questions about this job�

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