ATSG Automatic Transmission Repair Manual PDF, 3-Speed, 4-Speed, 4F20E, 4F27E, 4HP-18 - MATSGALLOPES.zip

An all-inclusive service and repair guide from ATSG Transmissions, containing every technical detail you need to service, troubleshoot, fix, and rebuild transmissions just like a seasoned professional technician.

Inside this ATSG Transmissions workshop service and repair manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 10,000+ pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

@Seminar Information@

7,706 pages, 311 MB PDF, 1988-2011

@Technical Service Bulletin@

214 MB PDF, 1986-2012

@Service Manual@

18,636 pages, 987 MB PDF

"3-SPEED.pdf" 87 pages

SUBARU 3 SPEED

This booklet contains general description and the procedures necessary to repair, overhaul, or service the three speed Subaru automatic transaxle. Although this transaxle comes in 2 wheel drive and 4 wheel drive the transfer case is not covered. The 3 speed transaxle have both lock-up and non-lock-up converters. The lock-up version is found in most 1986-UP models.

"4 HP 18 SUPPLEMENT.pdf" 48 pages

SAAB 9000 SUPPLEMENT

The Saab 4-HP-18 is a four speed automatic transmission designed for front wheel drive transversely mounted engine vehicles. A fluid coupling (torque converter) is used to transmit power from the engine into the transmission via the turbine shaft. Built into the torque converter is a damper plate that connects the 3/4 clutch drum shaft mechanically to the crank shaft so as to drive the 3/4 clutch drum at crankshaft speed . The damper plate is also used to prevent a 2-3 and 3-4 shift shock. The converter also drives a positive displacement pump to provide the transmission with fluid pressure. The 4-HP-18 uses a Ravigneaux planetary gear train consisting of sun gears, planet gears, I planet carrier and 1 ring gear. The different ratios are obtained through this gear train by the driving and holding of specific elements in this gear set. This

driving and holding of specific elements in the gear set is accomplished by the use of 5 different clutch packs, 1 band and 2 one-way holding devices.

The purpose of this supplemental manual is to show the engineering differences of the Saab 9000 version of the 4-HP-18 transmission. For tear down and reassembly, use the ATSG Eagle Premier, Dodge Monaco Tectran Manual on the 4-HP-18.

"4-SPEED.pdf" 96 pages

SUBARU 4 SPEED 1990-1997

This booklet contains general description and the procedures necessary to repair, overhaul, or service the 1990-97 Subaru 4 speed electronic automatic overdrive transmission. The Subaru 4 speed is a fully automatic front or All wheel drive transmission. This unit is based on the Nissan RE4R01A platform. The shift pattern is controlled electronically with a Transmission Control Module. The TCM will vary shift points, as it is constantly interpreting numerous electronic signals from various operational sensors located on the vehicle. The TCM also controls the apply and release of the Transfer Clutch which on All wheel Drive models controls the rear drive shaft output for 4 wheel drive.

"4F20E.pdf" 120 pages

FORD 4F20E

The 4F20E electronically controlled automatic transaxle features a combination of electronic and mechanical systems to control forward gear shifting torque converter lock-up for quietness and economy and self diagnosis capability for simplifying trouble shooting procedures. The electronic system controls the transaxle shifting in forward speeds and controls torque converter lock-up by means of solenoid actuated valves. These shift solenoid valves, when activated apply the friction elements (clutches and bands) to control shifting in the planetary gear. The shift timing and lock-up events are regulated by the TCM in programmed logic and in response to input sensors and switches to produce optimum performance.

"4F27E.pdf" 112 pages

Ford Motor Company in a joint venture with Mazda in Japan have developed a new design transaxle designed specifically for use in the Ford Focus, with the designation 4F27E, and Mazda designation is FN4A-EL. The new 4F27E transaxle is produced by Ford Motor Company in Sterling Heights, Michigan.

This is a four speed, Front Wheel Drive, with fully electronic controls for the upshifts and downshifts, with 4th gear being overdrive. The individual gear ratios are achieved through two planetary gear sets connected one behind the other. The components of the planetary gear sets are driven or locked by means of four multiple plate clutches, one brake band and a one-way roller clutch. To minimize fuel consumption, the torque converter clutch is applied by the PCM in 3rd and 4th gears, depending on throttle position and vehicle speed. This unit is designed to use Mercon® V automatic transmission fluid.

The manual selector lever gives the driver a choice of "P", "R", "N", "D", "2", "1", and all ranges are explained in detail in this manual. It is also possible to operate an O/D cancel switch, located on the selector lever, to prevent the transaxle from shifting into 4th gear or to shift down to 3rd gear.

"4HP18-22-24.pdf" 160 pages

BMW, AUDI, PORSCHE Technicians Guide INDEX

ZF 4HP-18FLE AND ZF 4HP-18 FLA DIAGNOSTIC INFORMATION

ZF 4HP-22/24 SERIES DIAGNOSTIC INFORMATION

MODEL “E-7” VALVE BODY WITH 5 SOLENOIDS

MODEL “E-9” VALVE BODY WITH 4 SOLENOIDS

ZF 5HP-18 DIAGNOSTIC INFORMATION

ZF 5HP-19FL DIAGNOSTIC INFORMATION

ZF 5HP-24 DIAGNOSTIC INFORMATION

ZF 5HP-30 DIAGNOSTIC INFORMATION

"4L30-E.pdf" 120 pages

THM 4L30-E

This booklet contains the general description and the procedures necessary to repair, overhaul, or service the Hydra-matic 4L30-E transmission that is currently found in the Opel Omega, Opel Senator, BMW, and the Isuzu Trooper/Rodeo. This transmission is a completely electronic controlled, 4 speed, rear wheel drive unit.

Gear ratios are as follows:

Opel/BMW

1st Gear 2.40

2nd Gear

3rd Gear

4th Gear

Reverse

Trooper/Rodeo

2.86

1.48 1.62

1.00 1.00

0.72 0.72

2.00 2.00

"4L60-E UPDATE HANDBOOK.pdf" 120 pages

THM 4L60-E/4L65-E

Since the introduction of the THM 4L60-E transmission in model year 1993, there have been many major engineering design changes to improve durability and reliability. These changes have affected nearly every part used in the THM 4L60-E. This "Update Handbook" will explain each change, the parts affected by the change, and any parts interchangeability concerns created by the change.

Beginning at the start of production for model year 2001, General Motors introduced a new transmission designated THM 4L65-E with many engineering changes. Currently this unit is found in all 2001 Cadillac Escalade and any vehicle with 6.0L engine or larger, that was previously equipped with the THM 4L60-E transmission. We will also cover the changes in the THM 4L65-E transmission in this booklet.

"4L60-E.pdf" 112 pages

THM 4L60-E

This booklet contains general description and the procedures necessary to repair, overhaul, or service the new THM 4L60-E electronic automatic overdrive transmission. The 4L60-E is a fully automatic rear wheel drive transmission. This unit is basically a THM 700-R4 with electronic controls added to the valve body. The shift pattern is controlled electronically with 2 shift solenoids that receive a ground signal from the Powertrain

Control Module (PCM). The PCM will vary shift points, as it is constantly interpreting numerous electronic signals from various operational sensors located on the vehicle.

The PCM also controls the apply and release of the Torque Converter Clutch (TCC). This transmission also received another PWM solenoid in 1995 to control TCC apply feel. Line pressure and shift feel are controlled electronically with a Pressure Control Solenoid (PCS), located on the valve body and dependent on TPS and VSS signals.

"4L60E-80E CODE BOOK.pdf" 185 pages

4L60E/65E/70E- 4L80E/85E DIAGNOSTIC CODE BOOK

The GM 4L60E/65E/70E-4L80E/85E Diagnostic Code Book is designed to provide the technician with a step by step diagnostic approach to each and every transmission code available from 1991 to the 2007 model year.

"4L80-E.pdf" 120 pages

THM 4L80-E

This booklet contains general description and the procedures necessary to repair, overhaul, or service the THM 4L80-E electronic overdrive automatic transmission. The THM 4L80-E is a fully automatic rear wheel drive transmission. It provides Park, Reverse, Neutral, and four forward speeds with 4th gear being overdrive.

The shift pattern is controlled electronically with two solenoids that receive a ground signal from the Powertrain Control Module (PCM). The PCM will vary shift points and shift feel, as it is constantly interpreting numerous electronic signals from various operational sensors located on the vehicle. The PCM also controls the Torque Converter Clutch (TCC) apply speed, apply feel, and the release electronically with a solenoid.

Line pressure and shift feel are also controlled electronically with a Pressure Control Solenoid (PCS) located on the valve body. This function is also controlled by the PCM and the numerous electronic signals from the sensors.

"4R44E-4R55E.pdf" 120 pages

FORD 4R44E/4R55E

The Ford 4R44E/4R55E is a fully electronic controlled, four speed, rear wheel drive transmission. At first glance it resembles the familiar A4LD transmission. The shift timing, shift feel, line pressure and TCC are all computer controlled in the 4R44E/4R55E transmissions. There are three compound planetary gearsets, three bands, three multi-disc clutch packs and two one-way freewheel assemblies.

"4R100.pdf" 120 pages

The Ford 4R100 transmission is an updated version of the E4OD and was first introduced in the 1999 model year, and is currently found in the F250, F350, F450 and F550 Super Duty trucks, E150, E250, E350, E450 vans and the Expedition/Navigator/Excursion vehicles equipped with the 5.4L, 6.8L, and 7.3L engines. Some of the 4R100 units are equipped with a Power-Take-Off (PTO) window on the left hand side of the transmission case.

The revisions in the 4R100 have created many new engineering changes that have affected many of the internal and external parts that will affect the servicing, repairing and overhaul of these units.

"4R100UPDATE HANDBOOK.pdf" 107 pages

FORD 4R100 "UPDATE HANDBOOK"

Since the introduction of the 4R100 transmission in model year 1998, there have been many engineering changes to improve Pleaseability, Reliability and Durability concerns. These changes have affected most every part used in this transmission. This "Update Handbook" will explain each change, the reason for the change, and any parts interchangeability concerns created by the change, along with any part numbers needed to update your transmission.

"4T40-E.pdf" 128 pages

THM 4T40-E

This booklet contains general description and the procedures necessary to repair, service, or overhaul the THM 4T40-E electronic overdrive automatic transaxle. This unit was first introduced in the 1995 Chevrolet Cavalier and Pontiac Sunfire vehicles, and will eventually replace the THM 125C (3T40).

The THM 4T40-E is a fully automatic front wheel drive transaxle. It provides park, reverse, neutral, and 4 forward speeds including overdrive. The shift pattern is controlled electronically with 2 shift solenoids that receive a ground signal from the Powertrain Control Module (PCM). The PCM will vary shift points, as it is constantly interpreting numerous electronic signals from various operational sensore located on the vehicle. The PCM also controls apply and release of the Torque Converter Clutch. Line pressure and shift feel are also controlled electronically with a Pressure Control Solenoid (PCS) located on the valve body and is dependant on TPS and VSS signals.

"4T60-E.pdf" 120 pages

THM 4T60-E

This booklet contains the procedures necessary to overhaul, repair or service the THM 4T60-E transaxle. The THM 4T60-E is a fully automatic front wheel drive transaxle that provides park, reverse, neutral and four forward speeds, with 4th gear being overdrive.

"4T65-E UPDATE HANDBOOK.pdf" 118 pages

THM 4T65-E UPDATE HANDBOOK

Since the introduction of the THM 4T65-E transmission in model year 1997, there have been many major engineering design changes to improve durability and reliability. These changes have affected many of the parts used in the THM 4T65-E. This "Update Handbook" will cover preliminary information and will also explain each change, the parts affected by the change, and any parts interchangeability concerns created by the change.

This manual is a companion manual to the 4T65-E Blue assembly and disassembly manual and is most helpful during a rebuild.

"4T65-E.pdf" 120 pages

THM 4T65-E

This booklet contains general description and overhaul procedures necessary to repair, overhaul or service the THM 4T65-E electronic overdrive automatic transaxle. This transaxle was introduced in the 1997 model year in several different models using the 3.8L supercharged engine and some models with the 3.8L and 3.4L engines. The THM 4T65-E is very similar to the 4T60-E and some of the parts are common with this unit. We wish to thank General Motors Corp. for the information and illustrations that have made this booklet possible.

"4T80-E.pdf" 112 pages

G.M. 4T80-E, THM 4T80-E

This booklet contains the general description, diagnosis charts, and the procedures necessary to overhaul, repair or service the General Motors THM 4T80-E four speed automatic overdrive transaxle. This information will assist you in training your technicians to provide your customers with the best possible transmission service that is available.

"5L40E-4L40E.pdf" 128 pages

HYDRA-MATIC 4/5L40-E

Beginning at the start of production for some 1999 models, BMW has introduced a new 5 speed automatic transmission that is designed and manufactured by General Motors Powertrain division in Strasbourg, France and is illustrated in Figure 1. This new transmission is designated as follows:

GM Designation - 5L40-E BMW Designation - A5S 360R

Model year 1999 applications are as follows:

Model year 2003 applications are as follows:

3 Series BMW, with 2.5L Gasoline Engine, Used in USA and Japan.

3 Series BMW, with 2.8L Gasoline Engine, Used in USA and Japan.

5 Series BMW, with 3.0L Diesel Engine, Used Worldwide.

Cadillac CTS model, Gasoline Engine, Used Worldwide

"5L40E.pdf" 128 pages

"5R55E.pdf" 120 pages

FORD 5R55E

The 5R55E transmission produced by Ford Motor Company, was introduced in the 1997 model year, and is the first 5 speed automatic found in domestic vehicles. It is currently found in the 1997 Aerostar Van, 1997-2001 Ranger Trucks, both 2WD and 4WD, and 1997-2001 Explorer vehicles, equipped with the 4.0L engine. This unit is very similar to the 4R44E, but has different computer strategy that energizes the overdrive band in first gear, to create the added gear ratio. Refer to the application chart found on Page 7 for the new computer strategy. Many of the parts between the 4R44E and 5R55E units may look the same, but are not all interchangeable. Be very careful when selecting replacement parts, if it becomes necessary.

"5R55N.pdf" 120 pages

FORD 5R55N

This booklet contains general description and overhaul procedures necessary to repair, overhaul or service the new Ford Motor Co 5R55N transmission. The Ford 5R55N transmission was first introduced in the 2000 model year, and is currently found in the Lincoln "LS" and Jaguar X200. We wish to thank Ford Motor Company for the information and illustrations that have made this booklet possible.

The 5R55N transmission has 5 forward speeds, reverse and is fully electronic controlled. Internally, it looks similar to the previous 5R55E unit, but very few minor components are actually the same. Following are the internal components used in the new 5R55N transmission.

3 Planetary Compound Gear Sets: Overdrive, Forward and Rear.

3 Brake Bands: Overdrive, Intermediate and Low/Reverse.

4 Multi-Plate Clutch Packs: Coast, Forward, Direct and Intermediate.

3 One-Way Clutches: Overdrive, Intermediate and Low.

Electronic Controlled Shifts, Torque Converter Clutch and Pressure.

"5R55W-5R55S.pdf" 120 pages

FORD 5R55S, FORD 5R55W

The Ford 5R55S and 5R55W transmissions are both very similar in design to the Ford 5R55N transmission and use electronic shift controls. The 5R55S/W are both "Syncrounous" units, as they do not use the intermediate clutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions were

introduced in 2002, found in the Ford Explorer and Mercury Mountaineer vehicles, and are available in both 2WD and 4WD configurations. For model year 2003 they are also in the Lincoln LS, Lincoln Aviator and Ford Thunderbird. They are designed for operation in longitudinal powertrains for rear wheel drive vehicles.

"5R110W.pdf" 120 pages

FORD 5R110W ("TorqShift")

The new Ford 5R110W, referred to by Ford Motor Company as the "TorqShift" transmission, is a redesign of the 4R100 transmission with some previous strategy applied. This unit was introduced in model year 2003 in the F Series Trucks and the Excursion vehicles that are equipped with the new 6.0L diesel engine. The

"TorqShift" (5R110W) is a 5 speed, rear wheel drive unit that actually has six forward speeds available, depending on hot or cold mode operation. The gear ratio for 1st gear was lowered from 2.71 to 3.09. For 2nd gear the overdrive clutch is applied to provide a ratio of 2.20. 3rd gear provides a ratio of 1.54, which is the same ratio as the previous second gear. All sound familiar? When in cold mode operation, below -15°C (5°F), determined by the TFT sensor, the overdrive clutch is engaged in 3rd gear to provide a ratio of 1.09 for 4th gear, and the transmission will shift directly into 6th gear (overdrive), which is a ratio of 0.71. In cold mode the transmission shifts 1st gear, 2nd gear, 3rd gear, 4th gear, 6th gear. When in hot mode the transmission will shift 1st gear, 2nd gear, 3rd gear, 5th gear (ratio 1.00), 6th gear. Either way it is still a five speed unit with six forward

gear ratios available, depending on cold mode or hot mode of operation.

"6HP26_TG.pdf" 73 pages

THE ZF6HP26 TRANSMISSION

BMW PRELIMINARY INFORMATION

The ZF Company has produced several 6 speed transmissions which are being used in car lines such as Jaguar, BMW, Volkswagen and Audi. Currently they have the 6HP19, the 6HP19FL and FLA, the 6HP26 and 6HP26A61, the 6HP32 and 32A. Although there are similarities among these units, they also have very significant differences. As a result, this short presentation will only be in regard to the 6HP26.

ZF6HP26 transmission within itself has several versions so as to accommodate the different car manufacturers and various engines they are fitted with, but the basic design and function of the transmission are the same.

"6L80.pdf" 108 pages

6L80 (6 Speed)

The new Hydra-matic 6L80 (6 Speed) is a fully automatic, six speed, rear wheel drive, electronic controlled transmission that features clutch to clutch shifting. It was first introduced in the 2006 Corvette with the 6.0L engine, Cadillac STSV/XLRV with the 4.4L engine, and is scheduled for Pick-ups in 2007, as shown in Figure 1. It consists primarily of a four element torque converter, two planetary gear sets, five clutch packs, one sprag and a hydraulic pressurization and control system. Two planetary gear sets provide the six forward gear ratios and reverse. Changing gear ratios is fully automatic and is accomplished through the use of a Transmission Control Module (TCM), that is located within the transmission. The TCM receives and monitors various electronic sensor inputs, and uses this information to shift the transmission at the optimum time. The TCM commands shift solenoids and variable bleed Clutch Pressure Control (CPC) solenoids within the transmission to control shift timing. The TCM controls shift feel through the CPC solenoids. The TCM also controls the apply and release of the torque converter clutch which allows the engine to deliver the maximum fuel efficiency without sacrificing vehicle performance. This manual contains procedures necessary to diagnose, overhaul and/or repair the new 6L80 (6 Speed) transmission from General Motors.

"09D.pdf" 136 pages

TOUAREG, AUDI Q7,

PORSCHE CAYENNE

TR60SN "09D" Transmission

The Japanese company AISIN Co., LTD is the manufacturer and developer of the Rear Wheel Drive TR60SN transmission, which is a 6 speed, fully automatic and electronic controlled transmission. Volkswagen engineers were also involved, in conjunction with Aisin, in the development process for their vehicles and Volkswagen gave it the "09D" designation.

The TR60SN, 09D transmission is used in a wide variety of applications and engine sizes. As a result, the number of friction plates, and planetary gears (3 or 4 pinion), will vary depending on torque load requirements of the specific vehicle. The TR60SN transmission uses a gear ratio sensitive system, requiring the correct transmission interchange. The TR60-SN is currently used in the Porsche Cayenne, Volkswagen Touareg, and Audi Q7 vehicles.

The 09D transmission uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux type, dual planetary. This is the same type of gear set that was used in the FMX. This arrangement makes six forward speeds and reverse possible, with only five clutch packs and one freewheel.

This manual contains the procedures necessary to diagnose, rebuild and/or repair the TR60SN "09D" transmission and is intended for automotive technicians that are familiar with the operation of automatic transmissions.

"09G.pdf" 124 pages

AUDI, JETTA, PASSAT,

09G/09M Transaxle

The Japanese company AISIN Co., LTD is the manufacturer and developer of the Front Wheel Drive TF60SN transaxle, which is a 6 speed, fully automatic and electronic controlled transaxle. Volkswagen engineers were also involved, in conjunction with Aisin, in the development process for their vehicles and they gave it the 09G/09M designation. BMW gave it the designation 6F21WA for their Mini-Cooper.

The 09G/09M transaxle is used in a wide variety of applications and engine sizes. As a result, the number of friction plates, planetary ratios, intermediate ratios and final drive ratios will vary depending on torque load requirements of the specific vehicle. The TF60SN transaxle uses a gear ratio sensitive system, requiring the correct transaxle interchange. The TF60-SN is used in the BMW Mini Cooper, Volkswagen and Audi vehicles. This transaxle is referred to as the TF60-SN, 09G, 09M, 6F21WA and in some overseas vehicles as 09K. As a result there are a variety of different case and part configurations. Some of these units have the heat exchanger attached to the transmission while others use a remote heat exchanger. This alters the case, case cover and the valve body and if incorrect parts are used, severe planetary failure will occur. This manual covers these differences so that this mistake will not happen to you.

The 09G/09M transaxle uses a Lepelletier arrangement, using a simple planetary coupled with a Ravigneaux planetary. This arrangement makes six forward speeds and reverse possible, with only five clutch packs and one freewheel.

This manual contains the procedures necessary to diagnose, rebuild and/or repair the 09G/09M transaxle and is intended for automotive technicians that are familiar with the operation of automatic transmissions.

"30-80LE.pdf" 120 pages

ISUZU AW30-80LE

The AW30-80LE is a rear wheel drive, four speed, electronically controlled, fully automatic transmission.

Internal components consist of a lock-up torque converter, oil pump, 5 multi-disc clutch packs, 1 brake band and three planetary gear sets. The valve body includes electronic solenoids for shift control that are controlled by a Transmission Control Unit (TCU). Shift control is determined by vehicle speed and throttle position sensor signals, that are constantly monitored by the TCU. Throttle cable is used for line pressure control.

"41_42 Series Automatic Transmission Repair (8169901121).pdf" 60 pages

This course provides hands on experience in the disassembly and assembly of the hydraulic and mechanical control systems of the 41TE/AE, 42LE & 42RLE transaxles. The goal of this course is to provide the technician with information and the tools to disassemble, reassemble and properly set-up the differentials of these transaxles. The 41TE/AE & 42LE transaxles are found on the following DaimlerChrysler vehicles:

Caravan/Voyager 41AE-AWD, 41TE-FWD

Cirrus/Stratus 41TE

Sebring Convertible 41TE

Neon 41TE

PT Cruiser 41TE

Intrepid/Concorde/300M 42LE

Wrangler 42RLE

This course contains six modules of training information:

Module 1 Disassembly of the 41/42 Series Electronic Automatic Transmissions

Module 2 Assembly of the 42LE Differential

Module 3 Assembly of the 41TE Differential

Module 4 Assembly of the Transmission’s Centerline

Module 5 Disassembly and Assembly of the Input Clutch Assembly

Module 6 Disassembly and Assembly of the Valve Body

"41TE CODE BOOK SPANISH.pdf" 96 pages

"41TE_42LE Operation and Diagnosis (8169901039).pdf" 42 pages

"41TE_AE & 42LE Transaxle Electronics (8169997107).pdf" 108 pages

"41TE-A604-42LE-A606 CODE BOOK.pdf" 96 pages

"41TE_AE & 42LE Transaxle Repair (8169997099).pdf" 56 pages

"42LE_A606.pdf" 103 pages

CHRYSLER 42LE (A-606)

The 42LE four speed transaxle has many similarities to the A-604. Both these units are fully computer controlled. The 42LE is mounted in the same fashion as the rear drive transmissions. That is NORTHSOUTH (longitudinally, whereas the A-604 is transverse mounted. Since the front axle of the vehicle passes through the bell housing the pump support shaft and the turbine shaft are longer.

"42RE ELEC GOVERNOR.pdf" 120 pages

FORD 5R55E

The 5R55E transmission produced by Ford Motor Company, was introduced in the 1997 model year, and is the first 5 speed automatic found in domestic vehicles. It is currently found in the 1997 Aerostar Van, 1997-2001 Ranger Trucks, both 2WD and 4WD, and 1997-2001 Explorer vehicles, equipped with the 4.0L engine. This unit is very similar to the 4R44E, but has different computer strategy that energizes the overdrive band in first gear, to create the added gear ratio. Refer to the application chart found on Page 7 for the new computer strategy. Many of the parts between the 4R44E and 5R55E units may look the same, but are not all interchangeable. Be very careful when selecting replacement parts, if it becomes necessary.

"42RE_A500SE_full.pdf" 106 pages

"42RE.pdf" 120 pages

CHRYSLER 42RE

The Chrysler 42RE (A500SE) is a 4 speed automatic transmission. Mechanical and hydraulic components in the 42RE are similar to those found in the 42RH (A500) transmissions. The major difference between them involves the method they use to produce governor pressure for shift control. The 42RE (A500SE) uses electronic components to create governor pressure and the 42RH (A500) uses a mechanical governor to create governor pressure.

First through third gear in the 42RE (A500SE) are provided by the clutches, bands, low roller clutch and planetary gear sets located in the transmission main case. Fourth gear is provided by the overdrive unit, located in the extension housing and contains an overdrive clutch, overdrive direct clutch, overrun roller clutch and overdrive planetary gear set. The 42RE

(A500SE) Overdrive Unit is shorter than the 42RH (A500), resulting from elimination of the mechanical governor, governor support and governor oil tubes.

"45RFE-545RFE.pdf" 120 pages

CHRYSLER 45RFE

Beginning at the start of production for the 1999 model year Chrysler Corporation has introduced a brand new rear wheel drive transmission for the 99 Jeep Grand Cherokee with the 4.7L engine, and scheduled for the Ram Pick-up for the 2000 model year. This is the first completely new rear wheel drive automatic transmission from Chrysler in more than thirty years. The 45RFE designation tells us that this new unit has 4 forward speeds, a relative torque rating of 5, is for Rear drive vehicles and is Fully Electronic controlled. Refer to Figure 1. The 545RFE was introduced in 2003 in 3.7 and 5.7 engines. There are few differences in the components between the 45RFE and the 545RFE, although the main difference is the addition of a fifth ratio, which is electronically controlled.

"45RFE.pdf" 112 pages

"46RE-47RE-48RE.pdf" 144 pages

46RE, 47RE, 48RE

The 46RE, 47RE and 48RE family of transmissions by the Chrysler Group, are fitted behind a wide variety of engine sizes, including diesel, and across various vehicle lines. They are also available in 2WD and 4WD configurations. Beginning at the start of production for model year 2005, Dodge trucks equipped with the 5.9L diesel and 48RE transmission were equipped with an electronically controlled Transmission Throttle Valve Actuator (TTVA). This Actuator has replaced the previous Throttle Valve Cable and all associated linkage. A push-in Transmission Range Sensor was implemented in model year 2002 to replace the screw-in Park/Neutral switch.

"68RFE.pdf" 112 pages

DODGE RAM 68RFE

Beginning at the start of production for the 2006 model year Chrysler Corporation has introduced a new version of the 5/45RFE transmission and is found in Dodge Ram trucks. The new 68RFE designation tells us that this new unit has 6 forward speeds, a relative torque rating of 8, is for Rear drive vehicles and is Fully Electronic controlled. Refer to Figure 1. The 68RFE transmission is a sophisticated, multi-range, electronically controlled transmission which combines optimized gear ratios for responsive performance, improved efficiency features, and low NVH (Noise, Vibration, Harshness). Other features include driver adaptive shifting and three, 6 pinion, planetary gear sets to provide wide ratio capability with precise ratio steps for optimum drivability. There have been several engineering changes in the geartrain to improve durability and reliability.

"096-097.pdf" 80 pages

V.W. AUDI PASSAT 095, 096, 097

The 095, 096 and 097 transmission is a fully electronic four speed automatic transaxle and is currently found in the Volkswagen Cabrio, Corrado, Golf, Jetta, Passat, and the Audi 80, 90, 100, and Cabriolet vehicles. This manual provides the information and procedures necessary to repair, overhaul and service this transaxle. Repairs should not be attempted by unqualified or untrained individuals. Standard safety precautions must be used in order to protect the vehicle and the individual doing the roper tools for the application, and the Original Manufacturers tool recommendations.

"125C UPDATE HANDBOOK.pdf" 86 pages

THM 12SC

Since the introduction of the THM 125 transaxle in model year 1980, there have been many major engineering changes. These changes have affected nearly every part used in the 125 and 125c. This Update Handbook will explain each change, the parts affected by the change, any parts interchangeability problems created by the change. This Update Handbook will cover all of the changes from start of production up through and including model year 1987, along with common problems, and fixes, for the THM 125 transaxle. The THM 125 was produced in model years 1980, 81 and early 1982. The THM 125C transaxle, introduced in early 1982, provided the addition of a converter clutch torque converter. The converter clutch was added to increase fuel economy by eliminating the fluid coupling of the transaxle at road load conditions, replacing it with a direct mechanical connection."

"125C.pdf" 96 pages

THM 125C (3T40)

This is booklet contains the general description, diagnosis and overhaul procedures necessary to repair, or service the THM 125C (3T40) transaxle. In addition to this booklet for the assembly and overhaul disassembly procedures, the Green Update Handbook available from ATSG is also necessary to inform you of the many engineering changes that have occured over the years. The THM 125C transaxle represents the addition of a converter clutch to the THM 125 transaxle that was introduced in 1980. The Torque Converter Clutch was added to increase fuel economy by eliminatin luid coupling of the transmission at road load conditions, replacing it with a direct mechanical connection.

"180C.pdf" 87 pages

THM 180 (TRl-MATIC)

This booklet contains the general description, diagnosis and overhaul procedures necessary to service the THM 180 and 180C (Tri-matic) transmission.

"200-4R.pdf" 96 pages

THM 200-4R

This booklet contains the general description, diagnosis charts, and the procedures necessary to overhaul, repair or service the General Motors THM 200-4R four speed automatic overdrive transmission. This information will assist you in training your technicians to provide your customers with the best possible transmission service that is available.

"200C.pdf" 80 pages

GENERAL MOTORS 200C

This contains the general description, diagnosis and overhaul procedures necessary to repair, overhaul or service this transmission.

"203-205.pdf" 39 pages

NEW PROCESS 203 -205

With more 4 wheel drive vehicles coming into our shops, the need for information on transfer cases has increased. Mike Weinberg of Rockland Standard Gear has gathered information on various types and model transfer cases that are most common. This series of booklets cover the general information, operation, tear down, and assembly of these units. And in most cases a parts breakdown is shown which helps in ordering replacement parts.

"231-241.pdf" 56 pages

NEW PROCESS 231-241

"350C.pdf" 82 pages

THM 350C

"400.pdf" 96 pages

THM 400

This booklet contains general description and overhaul procedures necessary to repair, overhaul or service the THM 400 transmission, and is found in both passenger cars and trucks. The THM 400 transmission was first introduced in 1964 and was used through the 1990 model year with some engineering changes that occurred during that time. We have included the major changes and updates in the appropriate sections of this booklet.

"404-470.pdf" 96 pages

CHRYSLER A-404/413/415/470

"404-670.pdf" 104 pages

CHRYSLER A404 thru A670

This booklet contains the general description, diagnosis, and assembly/disassembly procedures necessary to repair, overhaul, or service the A404, A413, A415, A470 and A670 transaxles. We have also included the updates and engineering changes that we are aware of, that have occured over the years.

"440-T4 UPDATE HANDBOOK VOL 1.pdf" 102 pages

"440-T4 UPDATE HANDBOOK VOL 2.pdf" 56 pages

"440-T4.pdf" 104 pages

THM 440-T4 (4T60)

This booklet contains the general description, diagnosis and overhaul procedures necessary to repair, overhaul, or service the THM 440-T4 overdrive automatic transaxle. The THM 440-T4 is a fully automatic front wheel drive transaxle. It provides Park, Reverse, Neutral and four forward speeds, with fourth gear being overdrive. Changing of the four forward gears is fully automatic, in relation to vehicle speed and throttle position. Vehicle Speed Signals (Governor), Throttle Position Signals (T.V. Cable), and Engine Torque Signals (Modulator) are constantly sent to the transaxle valve body to provide the proper gear ratio for maximum efficiency and performance at all throttle openings.

"700-R4-4L60 82 - 86.pdf" 96 pages

THM 700-R4 (4L60) 1982-1986

The THM 700-R4 transmission is a fully automatic unit consisting of a 3 element torque converter with the addition of a converter clutch.

"700-R4-4L60 87 - 93.pdf" 119 pages

GENERAL MOTORS 700-R4 1987-1993

This booklet contains general description and procedures necessary to repair, overhaul, or service the 1987-1993 THM 700-R4 transmission and includes all design levels.

"700-R4-4L60 UPDATE HANDBOOK.pdf" 120 pages

'82-'93 THM 700-R4 (4L60) UPDATE HANDBOOK

The 1987 through 1993 THM 700-R4 transmissions were produced with many engineering design changes. These changes have affected nearly every part used in the 700-R4. This "Update Handbook" will explain each change, the reason for the change, the parts that are affected by the change and any parts interchangeability concerns created by the change. 1993 was the last year the 700-R4 transmission was produced and this manual will cover all changes up through and including the 1993 changes.

"722-3-4.pdf" 120 pages

MERCEDES 722.3, 722.4

Mercedes first introduced the 722 models in model year 1980. The 722.3 is found in most models and the 722.4 is found in the 190 vehicles. This manual covers the procedures necessary to overhaul and repair both of these units. This manual also covers the differences between the units in the valve body and governor. The basic internal components such as the pump, gear-sets, drums clutches and bands are the same. This manual includes both the original manufacturers information along with some of the engineering changes and updates.

"722-5.pdf" 104 pages

MERCEDES 722.5

Mercedes introduced the five speed automatic overdrive transmission in the 1989 model year. At a quick glance it looks the same as the four speed 722.3 and 722.4 models. The extension housing is the quickest way to identify the five speed unit, as this is where the overdrive section was added. The 4-5 and the 5-4 shifts are a computer module. This manual covers the testing, disassembly, inspection and reassembly of the Mercedes 722.5 unit.

"722-6.pdf" 120 pages

MERCEDES, JAGUAR, DAIMLER/CHRYSLER "722.6" "5 Speed"

The Mercedes 722.6 transmission made its first debut here in the United States in 1996. It is used behind 4, 6, 8 and 12 cylinder gasoline engines, as well as their diesel engines. It is their first completely computer controlled transmission and their first to have a transmission with a converter clutch. This electronically controlled 5 speed automatic transmission consists of 3 compound planetary gear sets, 3 multiple disc driving clutches, 3 multiple disc brake clutches and 2 free-wheel clutches, with 5th gear being overdrive. The Electronic Transmission Controller (ETC) controls transmission operation matching engine performance during the shift phase. The driver can choose between 2 driving programs, S for standard driving programs and W for winter driving programs. Winter option provides a second gear start and a higher gear ratio for a reverse movement. Standard mode provides a first gear take off and a lower reverse gear ratio.

"722-8TG.pdf" 48 pages

The 722.8 is Mercedes Front Wheel Drive Continuous Variable Transmission.

"722.9.pdf" 28 pages

"A4LD-UPDATE HANDBOOK.pdf" 110 pages

Since the start of production in 1985, the FORD A4LD transmission has received many major engineering design changes. These design level changes have affected nearly every part used in the A4LD transmission. This "Update Handbook" will explain the purpose of each change, the parts that are affected by the change, and any parts interchangeability problems created by the change.

"A4LD.pdf" 112 pages

FORD A4LD

This booklet contains the general description, diagnosis, repair and overhaul procedures necessary to service the Ford A4LD overdrive transmission.

"A40-41-A40D-43DE.pdf" 112 pages

TOYOTA/VOLVO A40 SERIES

TOYOTA/VOLVO A40/A41-A43D/A43DE/AW70/AW71

The A40 Series of transmissions are covered in this manual. In the teardown and assembly section we are using an A43D transmission. We refer to the different valve body configurations where applicable. Although the A40 and A41 do not have the overdrive unit, the assembly is very similar. The A40 series transmissions are found in Toyota and Volvo vehicles. The units have minor differences and use different gaskets and seals. The Volvo unit may be referred to as the BW55, Not to be confused with the A55 (Tercel). We have illustrated the gaskets for the various valve bodies in a separate section in this manual. This section also shows valve body disassembly. There have been many gasket and seal changes on these models. We advise you to check the gaskets f the original unit, and compare them with the replacement gaskets to ensure that correct gaskets are installed.

"A55.pdf" 85 pages

TOYOTA A-55 TRANSAXLE

The A-55 Transaxle is a front wheel drive fully automatic transmission with both 2 and 4 wheel drive applications. Troubleshooting, teardown-assembly, removal and installation is fully covered.

"A130.pdf" 89 pages

TOYOTA A-130 TRANSAXLE

"A140.pdf" 102 pages

TOYOTA A140/A140E

"A240.pdf" 88 pages

TOYOTA A240

"A340 E-H.pdf" 96 pages

TOYOTA A-340 EH

The Toyota A-340 E and A-340 H automatic overdrive unit was designed for use in trucks. The unit comes with either computer controls (E) or hydraulic controls (H). This unit was introduced in 1985 vehicles. This booklet covers teardown and assembly of both the 340 E and 340 H models.

"A340-E TRANSFER CASE.pdf" 64 pages

A340H - A55 A WD

In the continuing process to keep the technician updated on the four wheel drive vehicles we now introduce the manual on the A350H transfer case which is found in Toyota and Isuzu models. This series of booklets cover the general information, operation tear down and assembly on these units. And in most cases a parts breakdown is shown which helps in ordering replacements parts. Also included in this manual is a breakdown and assembly of the all wheel drive found in the Tercel with the Asian A-55 automatic transmission.

"A340E.pdf" 96 pages

TOYOTA A-340 EH

"A440-F.pdf" 96 pages

TOYOTA A-440F

"A500-42RH-A518-46RH-A628-47RH.pdf" 90 pages

42RH (A500) - 46RH (A518) - 47RH (A618)

The A500 (42RH) (A999 Family) and A518 (46RH) (A727 Family) are both rear wheel drive transmissions with the overdrive section incorporated in the extension housing, and first made their appearance in 1988. The A500, beginning at start of production, was designed with a new electronic controlled 3-4 shift and electronic controlled converter clutch. The A518 however only received the electronic controlled 3-4 shift and in 1992 received the electronic controlled converter clutch. The A500 and A518 transmissions are found in the Dakota, Pick-up Trucks, Ramchargers, Vans and Ram-50 vehicles. In the Ram-50's, the transmission is referred to as the R4AC1 for 2WD versions and the V4AC1 for 4WD applications. A larger version of the A518 (46RH), known as the A618 (47RH), which basically has more clutch plates for increased torque carrying behind 5.9L Kumin$ diesel engines and the 8.0L pickup trucks."

"A500.pdf" 88 pages

"A540-E.pdf" 95 pages