5L40E Parts

Wir bringen Getriebe in Fahrt!We make transmissions drive!

Ihr Spezialist fr Automatikgetriebe

Your Specialist for Automatic Transmissions

5L40E TEILELISTE5L40E PARTSLIST

Fahrzeugtechnik Hetzel76698 Ubstadt-WeiherSchulstrae 25Telefon: +497251 61820Fax: +497251 618229E-Mail: [email protected]

115

ILLUSTRATED PARTS LIST

113

17 LOW CLUTCH ROLLER THRUST BEARING

20 INPUT AND REACTION CARRIER THRUST BEARING


26 OUTPUT SHAFT BEARING


201 INPUT SHAFT BEARING ASSEMBLY

215 TURBINE SHAFT BUSHING

226 TORQUE CONVERTER BUSHING

400 REVERSE CLUTCH HOUSING BUSHING

435 FORWARD CLUTCH BUSHING

456 FORWARD CLUTCH ROLLER INNER BEARING

461 FORWARD CLUTCH SPRAG ASSEMBLY

465 INPUT AND REACTION CARRIER BUSHING ASSEMBLY

bushbrngloc

Bushing and Bearing Locations

Figure 109

473 INTERMEDIATE CLUTCH SPRAG ASSEMBLY

476 INTERMEDIATE CLUTCH ROLLER THRUST BEARINGASSEMBLY

503 LOW CLUTCH SPRAG ASSEMBLY

519 INPUT AND REACTION BEARING ASSEMBLY


542 2ND CLUTCH ROLLER INNER RACE BEARINGASSEMBLY

547 2ND CLUTCH SPRAG ASSEMBLY

548 INPUT AND REACTION CARRIER BUSHING

552 REACTION CARRIER BUSHING



400 461 473503 542 547

56117 20 23 28

476

456435 465 465

519 541 548552 552

55426201

215 226

5L40-EONLY

5L40-EONLY

Bushing and Bearing Locations17 LOW CLUTCH ROLLER THRUST BEARING20 INPUT AND REACTION CARRIER THRUST BEARING 9602005423 INPUT AND REACTION CARRIER THRUST BEARING 9602023726 OUTPUT SHAFT BEARING28 OUTPUT SHAFT BEARING 96020238201 INPUT SHAFT BEARING ASSEMBLY 96020385215 TURBINE SHAFT BUSHING 8628047226 TORQUE CONVERTER BUSHING 96020365400 REVERSE CLUTCH HOUSING BUSHING 96020344435 FORWARD CLUTCH BUSHING456 FORWARD CLUTCH ROLLER INNER BEARING 96022593461 FORWARD CLUTCH SPRAG ASSEMBLY 96024629465 INPUT AND REACTION CARRIER BUSHING ASSEMBLY 96020272473 INTERMEDIATE CLUTCH SPRAG ASSEMBLY 96024629476 INTERMEDIATE CLUTCH ROLLER THRUST BEARING 96021053ASSEMBLY503 LOW CLUTCH SPRAG ASSEMBLY 96024631519 INPUT AND REACTION BEARING ASSEMBLY 96020152541 INPUT AND REACTION BEARING ASSEMBLY 96020142542 2ND CLUTCH ROLLER INNER RACE BEARING 96020141ASSEMBLY547 2ND CLUTCH SPRAG ASSEMBLY 96024630548 INPUT AND REACTION CARRIER BUSHING 96024902552 REACTION CARRIER BUSHING 96020084554 INPUT AND REACTION BEARING ASSEMBLY 96020086561 INPUT AND REACTION CARRIER BUSHING 96020052

114

402 REVERSE CLUTCH PISTON INNER SEAL

404 REVERSE CLUTCH PISTON

406 DIRECT CLUTCH PISTON ASSEMBLY

430 INPUT SHAFT (O-RING) SEAL431 INPUT SHAFT FLUID SEAL RING

432 INPUT SHAFT FLUID SEAL RING

436 FORWARD CLUTCH PISTON ASSEMBLY

438 COAST CLUTCH PISTON ASSEMBLY

487 OVERDRIVE CLUTCH PISTON ASSEMBLY

495 INTERMEDIATE CLUTCH PISTON ASSEMBLY

517 LOW AND REVERSE CLUTCH PISTON

520 2ND CLUTCH PISTON

528 2ND COAST CLUTCH PISTON ASSEMBLY

605 MANUAL SHIFT SHAFT SEAL

4 TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY

29 TRANSMISSION PROP SHAFT FLANGE SEAL

32 TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL38 CENTER SUPPORT FLUID PASSAGE SLEEVE

39 OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE

56 A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2)57 TRANSMISSION FILTER SEAL (2)64 A/TRANS FLUID PAN DRAIN PLUG SEAL

200 REVERSE CLUTCH HOUSING FLUID SEAL RING

218 A/TRANS FLUID PUMP SLIDE SEAL

220 A/TRANS FLUID PUMP SLIDE RING

229 TORQUE CONVERTER HOUSING SEAL

242 A/TRANS FLUID PUMP SLIDE O-RING SEAL

314 CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

316 CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

sealloc

Seal Locations

Figure 110

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200 404 406 436 487 495 5174 528 520

29 32

5L40-EONLY

605

Seal Locations

4 TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY 9602040929 TRANSMISSION PROP SHAFT FLANGE SEAL 9602545732 TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL 9602074538 CENTER SUPPORT FLUID PASSAGE SLEEVE 9602044039 OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE 9602117556 A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2) 9604205957 TRANSMISSION FILTER SEAL (2) 9602118764 A/TRANS FLUID PAN DRAIN PLUG SEAL 90528145200 REVERSE CLUTCH HOUSING FLUID SEAL RING 96020408218 A/TRANS FLUID PUMP SLIDE SEAL 8631282220 A/TRANS FLUID PUMP SLIDE RING 96020367229 TORQUE CONVERTER HOUSING SEAL 96020366242 A/TRANS FLUID PUMP SLIDE O-RING SEAL 96020368314 CLUTCH ACCUMULATOR PISTON FLUID SEAL RING 96020469316 CLUTCH ACCUMULATOR PISTON FLUID SEAL RING 96021045402 REVERSE CLUTCH PISTON INNER SEAL 96020345404 REVERSE CLUTCH PISTON 96021219406 DIRECT CLUTCH PISTON ASSEMBLY 96021174430 INPUT SHAFT (O-RING) SEAL 96013953431 INPUT SHAFT FLUID SEAL RING 96020330432 INPUT SHAFT FLUID SEAL RING 96020329436 FORWARD CLUTCH PISTON ASSEMBLY 96023901438 COAST CLUTCH PISTON ASSEMBLY 96020306487 OVERDRIVE CLUTCH PISTON ASSEMBLY 96025338495 INTERMEDIATE CLUTCH PISTON ASSEMBLY 96020682517 LOW AND REVERSE CLUTCH PISTON 96022480520 2ND CLUTCH PISTON 96024086528 2ND COAST CLUTCH PISTON ASSEMBLY 96025338605 MANUAL SHIFT SHAFT SEAL 8644709

1-TORQUE CONVERTER

REF: TYPE24212840 245MM24213033 245MM24215581 245MM24216768 258MM VT/VY/WN/WG/WZ/XD/XF/XW/ZM/ZO24219490 245MM24219491 245MM24225976 258MM24229970 258MM24233966 258MM

3- TORQUE CONVERTER HOUSING ASSEMBLY

REF:960235189602512796023655 SW/SX/VN/VM/VU/TZ/VP/VO/WU/WV/XL/XH/XA/XC/XE/XU/XX/XV/XB/YW/YX/YZ/VL/ZP/ZV/ZW/ZX/ZY/AW/NE96025667

7-INPUT SHAFT ASSEMBLY

REF9602511196024643960247379602464496024645

15- HSG ASM-O/D CLUTCH

REF960208099602256496022818960230769602464796024648

18-SUPPORT CENTER ASSEMBLY

REF96024704960247059602470696024707960247089602492496024926960250429602513596025241

21-OUT,SH GEAR ASM

REF96024429960244439602526496025265960252669602533796025414960254159602366796023948960239889602404996024429960244339602462696025262960252639602526796025337

FOR MODEL TRANSMISSION

FOR MODEL TRANSMISSIONXK/YN/YR/ZL

VT/VY/WN/WG/WZ/XD/XF/WX/XW/ZR/YV/YY/ZM/ZO/MS/MR/MS/YU

XK/YRYV/YY

YUMR/MS

SX/WP/XA/XV/YW/ZP/ZVVM/WV/XL/XB//NE

YU

FOR MODEL TRANSMISSIONYU

VN/VU/XZ/XH/XK/XU/XX/XV/XB/YN/YR/YW/YX/YZ/ZL/ZV/ZW

TZ/WU/XC/XE/XU/XX/YX/YZ/ZW

YN/ZL

XW/YV/YY/ZM/ZO/MR/MS

VT/WB/VY/WN/WG/WZ/XD/XF/WXSW/SX/VM/TZ/VP/VO/WU/WV/XA/XC/XE/VL/ZP/ZX/ZY/AW/

FOR MODEL TRANSMISSIONSW/SX/WN

VU/XHVN/VM/VT/WB/VY/VP/VO/WG/WZ/WV/XL/XA/XD/XF/XK/WX

TZ/WU/XC/XEXW/XV/YV/YY/YN/YR/YU/YW/ZM/ZO/ZV

XU/XX/YX/YZ/ZW

FOR MODEL TRANSMISSIONVT/VY/WN/WG/WZ/XD/XF

SW/SX/VM/WB/VP/VOVN

VU/XHTZ/WU/XC/XE/VL

XW/YU/YY/ZM/MS/MRXU/XX/YX/YZ/ZW/

XL/XK/ZLWV/XA/WX/ZP

XV/XB/YU/YW/ZO/ZU

FOR MODEL TRANSMISSIONYV/ZM/ZO/MS

XWXB/YN/YR/YV/ZV/ZW

XX/XV/ZXXUYZ

YW/YX/ZY/AWYY/MR

SW/SX/VN/VM/VT/WN//VP/VOVU/XH

XFVY/XD

YV/ZM/ZO/MS

WB/WU/WV/XL/XK/WX/ZL/ZPYZ

XWWG/WZTZ/XE

XA/XC/VL

116

assmpart_explode

Case and Associated Parts

Figure 111

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-EO

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-EO

NLY

4L40

-EO

NLY

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6061 6

2

64 6365

5L40

-ESO

ME

MO

DELS

6061 6

2

64 6365

5757 58

66

4L40

-EO

NLY

117

Case and Associated Parts Legend1 TORQUE CONVERTER ASSEMBLY

2 TORQUE CONVERTER HOUSING TO MAIN CASE BOLT

3 TORQUE CONVERTER HOUSING ASSEMBLY

4 TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY

5 REVERSE CLUTCH HOUSING THRUST WASHER(SELECTIVE)

6 DIRECT AND REVERSE CLUTCH ASSEMBLY

7 FORWARD AND COAST (W/CLUTCH ASSEMBLY)

8 INPUT SUN GEAR (W/FORWARD CLUTCH ROLLERINNER RACE) SHAFT

9 DIRECT CLUTCH HUB THRUST WASHER

10 DIRECT CLUTCH (W/INPUT AND REACTION CARRIER IN)HUB

11 INPUT AND REACTION CARRIER INNER SHAFTTHRUST WASHER


14 INTERMEDIATE AND OVERDRIVE CLUTCH HOUSINGRETAINER RING (SELECTIVE)

15 OVERDRIVE CLUTCH HOUSING

16 LOW CLUTCH SPRAG

17 LOW CLUTCH ROLLER THRUST BEARING

18 CENTER SUPPORT

19 INPUT AND REACTION CARRIER


21 OUTPUT SHAFT ASSEMBLY (W/REAR INTERNAL GEAR)

22 INPUT AND REACTION CARRIER WASHER (SELECTIVE)


24 A/TRANSMISSION CASE

25 A/T CASE EXTENSION GASKET


27 TRANSMISSION CASE EXTENSION


29 TRANSMISSION PROP SHAFT FLANGE SEAL

30 OUTPUT SHAFT ASSEMBLY RETAINER

31 TRANSMISSION PROP SHAFT FLANGE

32 TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL

33 TRANSMISSION PROP SHAFT THRUST WASHER

34 PROP SHAFT FLANGE NUT

35 A/T CASE EXTENSION BOLT

36 TRANSMISSION LEVEL HOLE PLUG

37 TRANSMISSION FLUID LEVEL HOLE PLUG O-RING

38 CENTER SUPPORT FLUID PASSAGE SLEEVE

39 OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE

40 TRANSMISSION PRESSURE TEST PLUG

41 OUTPUT SPEED SENSOR SPACER

42 OUTPUT SPEED SENSOR

43 OUTPUT SPEED SENSOR BOLT

44 INPUT SPEED SENSOR

45 INPUT SPEED SENSOR BOLT

46 TRANSMISSION FLUID PUMP COVER GASKET

47 CONTROL VALVE BODY AND ACCUMULATOR ASSEMBLY

49 CONTROL VALVE BODY BOLT



52 MANUAL SHAFT DETENT ASSEMBLY


54 WIRING HARNESS CLIP

55 A/TRANSMISSION WIRING HARNESS

56 A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2)

57 TRANSMISSION FILTER SEAL (2)

58 TRANSMISSION FILTER SPACER

59 A/TRANSMISSION FLUID FILTER

60 A/TRANS FLUID PAN GASKET

61 A/TRANS FLUID PAN MAGNET

62 A/TRANS FLUID PAN ASSEMBLY

63 A/TRANS FLUID PAN DRAIN PLUG

64 A/TRANS FLUID PAN DRAIN PLUG SEAL

65 A/TRANS FLUID PAN BOLT

66 TRANSMISSION PRESSURE TEST PLUG O-RING SEAL

Case and Associated Parts1 TORQUE CONVERTER ASSEMBLY2 TORQUE CONVERTER HOUSING TO MAIN CASE BOLT 960254723 TORQUE CONVERTER HOUSING ASSEMBLY4 TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY 960204095 REVERSE CLUTCH HOUSING THRUST WASHER(SELECTIVE) 96022647/48/49/50/51/52/24387/243886 DIRECT AND REVERSE CLUTCH ASSEMBLY 960247107 FORWARD AND COAST (W/CLUTCH ASSEMBLY) 960246468 INPUT SUN GEAR (W/FORWARD CLUTCH ROLLER 96025215INNER RACE) SHAFT9 DIRECT CLUTCH HUB THRUST WASHER 9602566210 DIRECT CLUTCH (W/INPUT AND REACTION CARRIER IN) 96024489HUB11 INPUT AND REACTION CARRIER INNER SHAFT 96022646THRUST WASHER12 INTERMEDIATE CLUTCH SPRAG ASSEMBLY 9602489514 INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING 96020033/34/35/503/504/505RETAINER RING (SELECTIVE)15 OVERDRIVE CLUTCH HOUSING16 LOW CLUTCH SPRAG 9602487117 LOW CLUTCH ROLLER THRUST BEARING 867788418 CENTER SUPPORT19 INPUT AND REACTION CARRIER 9602479420 INPUT AND REACTION CARRIER THRUST BEARING 9602005421 OUTPUT SHAFT ASSEMBLY (W/REAR INTERNAL GEAR)22 INPUT AND REACTION CARRIER WASHER (SELECTIVE) 96020242/43/44/45/46/4723 INPUT AND REACTION CARRIER THRUST BEARING24 A/TRANSMISSION CASE25 A/T CASE EXTENSION GASKET 9602587526 OUTPUT SHAFT BEARING 9602023627 TRANSMISSION CASE EXTENSION28 OUTPUT SHAFT BEARING 9602023829 TRANSMISSION PROP SHAFT FLANGE SEAL 9602545730 OUTPUT SHAFT ASSEMBLY RETAINER 9602261231 TRANSMISSION PROP SHAFT FLANGE32 TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL 9602074533 TRANSMISSION PROP SHAFT THRUST WASHER 9602363434 PROP SHAFT FLANGE NUT 9602225835 A/T CASE EXTENSION BOLT 9602547236 TRANSMISSION LEVEL HOLE PLUG 9602283537 TRANSMISSION FLUID LEVEL HOLE PLUG O-RING38 CENTER SUPPORT FLUID PASSAGE SLEEVE 9602044039 OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE 9602117540 TRANSMISSION PRESSURE TEST PLUG 9602505141 OUTPUT SPEED SENSOR SPACER42 OUTPUT SPEED SENSOR 9602252743 OUTPUT SPEED SENSOR BOLT 9602505244 INPUT SPEED SENSOR 9602252745 INPUT SPEED SENSOR BOLT 9602505246 TRANSMISSION FLUID PUMP COVER GASKET 9602041047 CONTROL VALVE BODY AND ACCUMULATOR ASSEMBLY49 CONTROL VALVE BODY BOLT 9602129050 CONTROL VALVE BODY BOLT 9602129051 CONTROL VALVE BODY BOLT 9602129052 MANUAL SHAFT DETENT ASSEMBLY 9602459353 CONTROL VALVE BODY BOLT 9602101254 WIRING HARNESS CLIP 9601792855 A/TRANSMISSION WIRING HARNESS 9602593956 A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2) 9604205957 TRANSMISSION FILTER SEAL (2) 9602118758 TRANSMISSION FILTER SPACER59 A/TRANSMISSION FLUID FILTER 9602259860 A/TRANS FLUID PAN GASKET 9602587661 A/TRANS FLUID PAN MAGNET 9602615862 A/TRANS FLUID PAN ASSEMBLY63 A/TRANS FLUID PAN DRAIN PLUG 9602326464 A/TRANS FLUID PAN DRAIN PLUG SEAL 9052814565 A/TRANS FLUID PAN BOLT 9602505066 TRANSMISSION PRESSURE TEST PLUG O-RING SEAL

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conv_hous_expl

Fluid Pump Assembly

Figure 112

119

200 REVERSE CLUTCH HOUSING FLUID SEAL RING

201 INPUT SHAFT BEARING ASSEMBLY

202 A/TRANS FLUID PUMP COVER ASSEMBLY

203 CHECK VALVE RETAINER AND BALL ASSEMBLY

204 VALVE BUSHING/SPRING RETAINER

205 LINE BOOST VALVE BUSHING SEAL

206 LINE BOOST VALVE BUSHING

207 LINE BOOST VALVE

208 LINE BOOST VALVE SPRING

209 PRESSURE REGULATOR VALVE SPRING

210 PRESSURE REGULATOR VALVE

211 A/TRANS FLUID PUMP RETAINER PIN

212 A/TRANS FLUID PUMP COVER SEAL

213 A/TRANS FLUID PUMP SCREEN ASSEMBLY

214 BRASS ORIFICE INSERT

215 TURBINE SHAFT BUSHING

216 A/TRANS FLUID PUMP SLIDE (SELECTIVE)

217 A/TRANS FLUID PUMP SLIDE SEAL SUPPORT

218 A/TRANS FLUID PUMP SLIDE SEAL

219 A/TRANS FLUID PUMP SLIDE SPRING

220 A/TRANS FLUID PUMP SLIDE RING

221 A/TRANS FLUID PUMP VANE RING

Fluid Pump Assembly Legend222 A/TRANS FLUID PUMP VANE

223 A/TRANS FLUID PUMP ROTOR (SELECTIVE)

224 A/TRANS FLUID PUMP ROTOR GUIDE

225 A/TRANS FLUID PUMP VANE RING

226 TORQUE CONVERTER BUSHING

227 TORQUE CONVERTER HOUSING

228 TORQUE CONVERTER HOUSING SEAL BOLT

229 TORQUE CONVERTER HOUSING SEAL

231 A/TRANS FLUID PUMP SLIDE PIN ASSEMBLY

232 ORIFICE SLEEVE

233 ORIFICE CUP PLUG

234 TCC CONTROL VALVE SPRING

235 TCC CONTROL VALVE

236 A/TRANS FLUID PUMP RETAINER PIN

237 TCC ENABLE VALVE

238 PRESSURE RELIEF BALL VALVE SPRING

239 PRESSURE RELIEF BALL VALVE

240 A/TRANS FLUID PUMP BOLT

241 A/TRANS FLUID PUMP BOLT

242 A/TRANS FLUID PUMP SLIDE O-RING SEAL

Fluid Pump Assembly

200 REVERSE CLUTCH HOUSING FLUID SEAL RING 96020408201 INPUT SHAFT BEARING ASSEMBLY 96020385202 A/TRANS FLUID PUMP COVER ASSEMBLY 96023661203 CHECK VALVE RETAINER AND BALL ASSEMBLY 96022410204 VALVE BUSHING/SPRING RETAINER 96020389205 LINE BOOST VALVE BUSHING SEAL 96021023206 LINE BOOST VALVE BUSHING 96021024207 LINE BOOST VALVE 96023703208 LINE BOOST VALVE SPRING 8680684209 PRESSURE REGULATOR VALVE SPRING 96020561210 PRESSURE REGULATOR VALVE 96022392211 A/TRANS FLUID PUMP RETAINER PIN 96022414212 A/TRANS FLUID PUMP COVER SEAL 8642581213 A/TRANS FLUID PUMP SCREEN ASSEMBLY 24210086214 BRASS ORIFICE INSERT 96023663215 TURBINE SHAFT BUSHING 8628047216 A/TRANS FLUID PUMP SLIDE (SELECTIVE) 24205405/06/07/08/09217 A/TRANS FLUID PUMP SLIDE SEAL SUPPORT 8631283218 A/TRANS FLUID PUMP SLIDE SEAL 8631282219 A/TRANS FLUID PUMP SLIDE SPRING 96020369220 A/TRANS FLUID PUMP SLIDE RING 96020367221 A/TRANS FLUID PUMP VANE RING 24201144

222 A/TRANS FLUID PUMP VANE 8631280223 A/TRANS FLUID PUMP ROTOR (SELECTIVE) 96024172/73/74/75/76224 A/TRANS FLUID PUMP ROTOR GUIDE 24205410225 A/TRANS FLUID PUMP VANE RING 24201144226 TORQUE CONVERTER BUSHING 96020365227 TORQUE CONVERTER HOUSING228 TORQUE CONVERTER HOUSING SEAL BOLT 96015215229 TORQUE CONVERTER HOUSING SEAL 96020366231 A/TRANS FLUID PUMP SLIDE PIN ASSEMBLY 96020370232 ORIFICE SLEEVE 96014328233 ORIFICE CUP PLUG 96014328234 TCC CONTROL VALVE SPRING 96020721235 TCC CONTROL VALVE 96022411236 A/TRANS FLUID PUMP RETAINER PIN 96022413237 TCC ENABLE VALVE 96022412238 PRESSURE RELIEF BALL VALVE SPRING 8634106239 PRESSURE RELIEF BALL VALVE 147500240 A/TRANS FLUID PUMP BOLT 96025473241 A/TRANS FLUID PUMP BOLT 96022408242 A/TRANS FLUID PUMP SLIDE O-RING SEAL 96020368

120

vb_explode

Control Valve Body and Accumulator Assembly

Figure 113

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5L40-EONLY

4L40-EONLY

5L40-EONLY

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121

Control Valve Body and Accumulator Assembly Legend300 CONTROL VALVE BODY BOLT

301 CONTROL VALVE TOP CHANNEL PLATE

302 CONTROL VALVE CHANNEL PLATE BALL CHECK SPRING

303 CONTROL VALVE CHANNEL PLATE GASKET

304 CONTROL VALVE BOTTOM CHANNEL PLATE

305 CONTROL VALVE BODY GASKET

306 CONTROL VALVE BODY BALL CHECK VALVE

307 CONTROL VALVE BODY SPACER PLATE

308 TCC PWM SOLENOID VALVE FILTER ASSEMBLY

309 CONTROL VALVE BODY SPACER PLATE GASKET

310 CONTROL VALVE REAR BODY

311 CONTROL VALVE FRONT BODY

312 PRESSURE CONTROL SOLENOID VALVE FILTERASSEMBLY

313 DIRECT CLUTCH ACCUMULATOR PISTON SPRING

314 DIRECT CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

315 DIRECT CLUTCH ACCUMULATOR PISTON

316 DIRECT CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

317 DIRECT CLUTCH ACCUMULATOR HOUSING

318 ACCUMULATOR HOUSING BOLT

319 OVERDRIVE CLUTCH ACCUMULATOR PISTON SPRING

320 OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

321 OVERDRIVE CLUTCH ACCUMULATOR PISTON

322 OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

323 OVERDRIVE CLUTCH ACCUMULATOR HOUSING

324 INTERMEDIATE CLUTCH ACCUMULATOR PISTONSPRING

325 INTERMEDIATE CLUTCH ACCUMULATOR PISTONFLUID RING

326 INTERMEDIATE CLUTCH ACCUMULATOR PISTON

327 INTERMEDIATE CLUTCH ACCUMULATOR PISTON FLUIDSEAL RING

328 INTERMEDIATE CLUTCH ACCUMULATOR HOUSING

329 2ND CLUTCH ACCUMULATOR PISTON SPRING

330 2ND CLUTCH ACCUMULATOR PISTON RING

331 2ND CLUTCH ACCUMULATOR PISTON

332 2ND CLUTCH ACCUMULATOR PISTON RING

333 2ND CLUTCH ACCUMULATOR HOUSING

Control Valve Body and Accumulator Assembly300 CONTROL VALVE BODY BOLT 96020027301 CONTROL VALVE TOP CHANNEL PLATE 96025489302 CONTROL VALVE CHANNEL PLATE BALL CHECK SPRING 96020952303 CONTROL VALVE CHANNEL PLATE GASKET 96020575304 CONTROL VALVE BOTTOM CHANNEL PLATE 96024109305 CONTROL VALVE BODY GASKET 96020573306 CONTROL VALVE BODY BALL CHECK VALVE 96020431307 CONTROL VALVE BODY SPACER PLATE 96025378308 TCC PWM SOLENOID VALVE FILTER ASSEMBLY 24209145309 CONTROL VALVE BODY SPACER PLATE GASKET 96020567310 CONTROL VALVE REAR BODY 96023540311 CONTROL VALVE FRONT BODY 96024276312 PRESSURE CONTROL SOLENOID VALVE FILTER 24209145ASSEMBLY313 DIRECT CLUTCH ACCUMULATOR PISTON SPRING 96020458314 DIRECT CLUTCH ACCUMULATOR PISTON FLUID 96020469SEAL RING315 DIRECT CLUTCH ACCUMULATOR PISTON 96021044316 DIRECT CLUTCH ACCUMULATOR PISTON FLUID 96021045SEAL RING317 DIRECT CLUTCH ACCUMULATOR HOUSING 96021042318 ACCUMULATOR HOUSING BOLT 96025325319 OVERDRIVE CLUTCH ACCUMULATOR PISTON SPRING 96022008320 OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUID 96020469SEAL RING321 OVERDRIVE CLUTCH ACCUMULATOR PISTON 96022007322 OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUID 96022003SEAL RING323 OVERDRIVE CLUTCH ACCUMULATOR HOUSING 96022005324 INTERMEDIATE CLUTCH ACCUMULATOR PISTON 96020458SPRING325 INTERMEDIATE CLUTCH ACCUMULATOR PISTON 96020469FLUID RING326 INTERMEDIATE CLUTCH ACCUMULATOR PISTON 96021044327 INTERMEDIATE CLUTCH ACCUMULATOR PISTON FLUID 96021045SEAL RING328 INTERMEDIATE CLUTCH ACCUMULATOR HOUSING 96021042329 2ND CLUTCH ACCUMULATOR PISTON SPRING 96020848330 2ND CLUTCH ACCUMULATOR PISTON RING 96020469331 2ND CLUTCH ACCUMULATOR PISTON 96020765332 2ND CLUTCH ACCUMULATOR PISTON RING 96020767333 2ND CLUTCH ACCUMULATOR HOUSING 96020761

122

vb2_disassembly

Front Control Valve Body

Figure 114

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340 CONTROL VALVE FRONT BODY

341 SAFETY MODE VALVE

342 SAFETY MODE VALVE SPRING

343 VALVE SPRING RETAINER

344 3-4 SHIFT VALVE SPRING

345 3-4 SHIFT VALVE

346 3-4 SHIFT CONTROL VALVE

347 TCC REGULATOR APPLY VALVE SPRING

348 TCC REGULATOR APPLY VALVE

349 SOLENOID VALVE (O-RING) SEAL


351 SOLENOID VALVE RETAINER

352 TCC PWM SOLENOID VALVE

353 FEED LIMIT VALVE

354 FEED LIMIT VALVE SPRING

355 PRESSURE CONTROL SOLENOID (O-RING) SEAL

356 PRESSURE CONTROL SOLENOID (O-RING) SEAL

357 PRESSURE CONTROL SOLENOID ASSEMBLY

Front Control Valve Body

340 CONTROL VALVE FRONT BODY 96024893341 SAFETY MODE VALVE 96023082342 SAFETY MODE VALVE SPRING 96020391343 VALVE SPRING RETAINER 96020446344 3-4 SHIFT VALVE SPRING 96020391345 3-4 SHIFT VALVE 96023082346 3-4 SHIFT CONTROL VALVE 96021252347 TCC REGULATOR APPLY VALVE SPRING 96022567348 TCC REGULATOR APPLY VALVE 96021256349 SOLENOID VALVE (O-RING) SEAL 96042803350 SOLENOID VALVE (O-RING) SEAL 96042804351 SOLENOID VALVE RETAINER 8680781352 TCC PWM SOLENOID VALVE 24227811353 FEED LIMIT VALVE 96023083354 FEED LIMIT VALVE SPRING 96023197355 PRESSURE CONTROL SOLENOID (O-RING) SEAL356 PRESSURE CONTROL SOLENOID (O-RING) SEAL357 PRESSURE CONTROL SOLENOID ASSEMBLY 10478146

123

vb1_disassembly

Rear Control Valve Body

Figure 115

343

388

387

343

386385

384

381 382383

377

378

379380

373374

375349

349

350

351

376

369

351350

370371

372

368

351

350

349

343

367366

365

343 VALVE SPRING RETAINER



351 SOLENOID VALVE RETAINER

365 CONTROL VALVE REAR BODY


367 1-2 SHIFT CONTROL VALVE SPRING

368 1-2 SHIFT SOLENOID VALVE ASSEMBLY



371 2-3 SHIFT VALVE



374 4-5 SHIFT VALVE



377 MANUAL VALVE

378 MANUAL VALVE LINK WASHER (WAVED)

379 MANUAL VALVE LINK

380 MANUAL VALVE LINK RETAINER

381 LOW PRESSURE CONTROL VALVE BORE PLUG

382 LOW PRESSURE CONTROL VALVE SPRING

383 LOW PRESSURE CONTROL VALVE

384 LOW PRESSURE CONTROL VALVE BORE RETAINER

385 REVERSE LOCKOUT VALVE

386 REVERSE LOCKOUT VALVE SPRING

387 1-2 SHIFT VALVE


Rear Control Valve Body

343 VALVE SPRING RETAINER 96020446349 SOLENOID VALVE (O-RING) SEAL 96042803350 SOLENOID VALVE (O-RING) SEAL 96042804351 SOLENOID VALVE RETAINER 8680781365 CONTROL VALVE REAR BODY 96023541366 1-2 SHIFT CONTROL VALVE 96021253367 1-2 SHIFT CONTROL VALVE SPRING 96020391368 1-2 SHIFT SOLENOID VALVE ASSEMBLY 96022804369 2-3 SHIFT SOLENOID VALVE ASSEMBLY 96022804370 2-3 SHIFT CONTROL VALVE 96021252371 2-3 SHIFT VALVE 96021250372 2-3 SHIFT VALVE SPRING 96020391373 4-5 SHIFT VALVE SPRING 96020391374 4-5 SHIFT VALVE 96023082375 4-5 SHIFT CONTROL VALVE 96021252376 4-5 SHIFT SOLENOID VALVE ASSEMBLY 96022804377 MANUAL VALVE 96021257378 MANUAL VALVE LINK WASHER (WAVED) 96026101379 MANUAL VALVE LINK 96024060380 MANUAL VALVE LINK RETAINER 96020898381 LOW PRESSURE CONTROL VALVE BORE PLUG 96020482382 LOW PRESSURE CONTROL VALVE SPRING 96024184383 LOW PRESSURE CONTROL VALVE 96021255384 LOW PRESSURE CONTROL VALVE BORE RETAINER 96020483385 REVERSE LOCKOUT VALVE 96022566386 REVERSE LOCKOUT VALVE SPRING 96020391387 1-2 SHIFT VALVE 96021250388 1-2 SHIFT VALVE SPRING 96020391

124

Partlist_A

Direct and Reverse Clutch Assembly

Figure 116

403

400

401

402

404405

406

407408

409

410

411

412

413

414

415

416

417

418

419

420

400 REVERSE CLUTCH HOUSING BUSHING

401 REVERSE CLUTCH (W/INPUT HOUSING ASSEMBLY)402 REVERSE CLUTCH PISTON INNER SEAL

403 REVERSE CLUTCH HOUSING BALL CHECK VALVE

404 REVERSE CLUTCH PISTON

405 DIRECT CLUTCH HOUSING BALL CHECK VALVE

406 DIRECT CLUTCH PISTON ASSEMBLY

407 DIRECT AND REVERSE CLUTCH SPRING

408 DIRECT AND REVERSE CLUTCH SPRING RETAINER

409 DIRECT AND REVERSE CLUTCH SPRING RETAINER RING

410 DIRECT CLUTCH APPLY PLATE

411 DIRECT CLUTCH PLATE ASSEMBLY (OUTER SPLINE)412 DIRECT CLUTCH PLATE ASSEMBLY (INNER SPLINE)413 DIRECT CLUTCH BACKING PLATE

414 DIRECT CLUTCH BACKING PLATE RETAINER RING(SELECTIVE)

415 REVERSE CLUTCH SPACER

416 REVERSE CLUTCH APPLY PLATE

417 REVERSE CLUTCH PLATE ASSEMBLY (OUTER SPLINE)418 REVERSE CLUTCH PLATE ASSEMBLY (INNER SPLINE)419 REVERSE CLUTCH BACKING PLATE

420 REVERSE CLUTCH BACKING PLATE RETAINER RING(SELECTIVE)

Direct and Reverse Clutch Assembly

400 REVERSE CLUTCH HOUSING BUSHING 96020344401 REVERSE CLUTCH (W/INPUT HOUSING ASSEMBLY) 96025258402 REVERSE CLUTCH PISTON INNER SEAL 96020345403 REVERSE CLUTCH HOUSING BALL CHECK VALVE 96025079404 REVERSE CLUTCH PISTON 96021219405 DIRECT CLUTCH HOUSING BALL CHECK VALVE 96025079406 DIRECT CLUTCH PISTON ASSEMBLY 96021174407 DIRECT AND REVERSE CLUTCH SPRING 96026037408 DIRECT AND REVERSE CLUTCH SPRING RETAINER 96020903409 DIRECT AND REVERSE CLUTCH SPRING RETAINER RING 96020067410 DIRECT CLUTCH APPLY PLATE 96026076411 DIRECT CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96024393412 DIRECT CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96024392413 DIRECT CLUTCH BACKING PLATE 96020158414 DIRECT CLUTCH BACKING PLATE RETAINER RING 96020160/61/579/580(SELECTIVE)415 REVERSE CLUTCH SPACER 96023996416 REVERSE CLUTCH APPLY PLATE 96026038417 REVERSE CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96020210418 REVERSE CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96020209419 REVERSE CLUTCH BACKING PLATE 96020211420 REVERSE CLUTCH BACKING PLATE RETAINER RING 96020174/75/76/77/78/79/80(SELECTIVE)

125

Forward and Coast Clutch Assembly

430 431432

433434 435

436437

438439

440

441

442

443444

445

446

447

448

449

450

451

430 INPUT SHAFT (O-RING) SEAL431 INPUT SHAFT FLUID SEAL RING

432 INPUT SHAFT FLUID SEAL RING

433 FORWARD CLUTCH (W/INPUT HOUSING ASSEMBLY)434 FORWARD CLUTCH HOUSING BALL CHECK VALVE

ASSEMBLY

435 FORWARD CLUTCH BUSHING

436 FORWARD CLUTCH PISTON ASSEMBLY

437 COAST CLUTCH PISTON BALL CHECK VALVEASSEMBLY

438 COAST CLUTCH PISTON ASSEMBLY

439 FORWARD AND COAST CLUTCH SPRING

Figure 117

Partlist_B

440 FORWARD AND COAST CLUTCH SPRINGRETAINER RING

441 COAST CLUTCH SPACER PLATE (SELECTIVE)442 COAST CLUTCH APPLY PLATE

443 COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE)444 COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE)445 COAST CLUTCH BACKING PLATE

446 COAST CLUTCH HOUSING

447 FORWARD CLUTCH APPLY PLATE

448 FORWARD CLUTCH PLATE ASSEMBLY (OUTER SPLINE)449 FORWARD CLUTCH PLATE ASSEMBLY (INNER SPLINE)450 FORWARD CLUTCH BACKING PLATE

451 FORWARD CLUTCH BACKING PLATERETAINER RING (SELECTIVE)

Forward and Coast Clutch Assembly

430 INPUT SHAFT (O-RING) SEAL 96013953431 INPUT SHAFT FLUID SEAL RING 96020330432 INPUT SHAFT FLUID SEAL RING 96020329433 FORWARD CLUTCH (W/INPUT HOUSING ASSEMBLY) 96025093434 FORWARD CLUTCH HOUSING BALL CHECK VALVE 96025079ASSEMBLY435 FORWARD CLUTCH BUSHING436 FORWARD CLUTCH PISTON ASSEMBLY 96023901437 COAST CLUTCH PISTON BALL CHECK VALVE 96025079ASSEMBLY438 COAST CLUTCH PISTON ASSEMBLY 96020306439 FORWARD AND COAST CLUTCH SPRING 96025391440 FORWARD AND COAST CLUTCH SPRING 96020066RETAINER RING441 COAST CLUTCH SPACER PLATE (SELECTIVE) 96020316/17/18/19/20/21442 COAST CLUTCH APPLY PLATE 96026040443 COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96024640444 COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96024639445 COAST CLUTCH BACKING PLATE 96020316446 COAST CLUTCH HOUSING 96020842447 FORWARD CLUTCH APPLY PLATE 96026039448 FORWARD CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96024638449 FORWARD CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96024637450 FORWARD CLUTCH BACKING PLATE 96020328451 FORWARD CLUTCH BACKING PLATE 96020167RETAINER RING (SELECTIVE)

126

455456

457

462

458

459

460

461

460

Direct Clutch Drum and Shaft Assembly

465

466 465

465 INPUT AND REACTION CARRIER BUSHING ASSEMBLY

466 DIRECT CLUTCH (W/INPUT AND HUB ASSEMBLY)Partlist_D

Figure 119

Input Sun Gear Shaft and Forward Sprag Clutch Assembly

455 FORWARD CLUTCH ROLLER INNER RACE THRUST RING

456 FORWARD CLUTCH ROLLER INNER BEARING

457 INPUT SUN GEAR SHAFT ASSEMBLY

458 FORWARD CLUTCH ROLLER OUTER RACE WASHER

459 FORWARD CLUTCH SPRAG OUTER RACE

460 FORWARD CLUTCH SPRAG ASSEMBLY RETAINERRINGS

461 FORWARD CLUTCH SPRAG ASSEMBLY

462 ORIFICED CUP PLUG (LUBE)Partlist_C

Figure 118

Input Sun Gear Shaft and Forward Sprag Clutch Assembly

455 FORWARD CLUTCH ROLLER INNER RACE THRUST RING 96020078456 FORWARD CLUTCH ROLLER INNER BEARING 96022593457 INPUT SUN GEAR SHAFT ASSEMBLY 96023664458 FORWARD CLUTCH ROLLER OUTER RACE WASHER 96022645459 FORWARD CLUTCH SPRAG OUTER RACE 96025657460 FORWARD CLUTCH SPRAG ASSEMBLY RETAINER 96024629RINGS461 FORWARD CLUTCH SPRAG ASSEMBLY 96024629462 ORIFICED CUP PLUG (LUBE) 96020280

Direct Clutch Drum and Shaft Assembly

465 INPUT AND REACTION CARRIER BUSHING ASSEMBLY 96024484466 DIRECT CLUTCH (W/INPUT AND HUB ASSEMBLY 96024489

127

Intermediate Sprag Clutch Assembly470

471

472

473

472

474

475

476477

Partlist_E

Figure 120

470 OVERDRIVE AND REVERSE CLUTCH (W/HUBASSEMBLY)

471 INTERMEDIATE CLUTCH ROLLER THRUST WASHER

472 INTERMEDIATE CLUTCH SPRAG ASSEMBLYRETAINER RINGS


474 INTERMEDIATE CLUTCH SPRAG OUTER RACE

475 INTERMEDIATE CLUTCH ROLLER THRUST WASHER

476 INTERMEDIATE CLUTCH ROLLER THRUST BEARINGASSEMBLY

477 INTERMEDIATE CLUTCH ROLLER THRUST BEARINGASSEMBLY RETAINER

Intermediate Sprag Clutch Assembly

470 OVERDRIVE AND REVERSE CLUTCH (W/HUB 96022642ASSEMBLY)471 INTERMEDIATE CLUTCH ROLLER THRUST WASHER 96022010472 INTERMEDIATE CLUTCH SPRAG ASSEMBLY 96024629RETAINER RINGS473 INTERMEDIATE CLUTCH SPRAG ASSEMBLY 96024629474 INTERMEDIATE CLUTCH SPRAG OUTER RACE 96025648475 INTERMEDIATE CLUTCH ROLLER THRUST WASHER 96022010476 INTERMEDIATE CLUTCH ROLLER THRUST BEARING 96021053ASSEMBLY477 INTERMEDIATE CLUTCH ROLLER THRUST BEARING 96021054

128

Overdrive and Intermediate Clutch Assembly

480

481

482

483

484

485

486

487

488

489490

491

492

493

494

495

496

497

Partlist_F

Figure 121

129

500501

502

502

504

501

505

503

Low Clutch Sprag Assembly

500 LOW CLUTCH ROLLER RETAINER

501 LOW CLUTCH ROLLER THRUST WASHER

502 LOW CLUTCH SPRAG ASSEMBLY RETAINER RINGSPartlist_G

Figure 122

503 LOW CLUTCH SPRAG ASSEMBLY

504 LOW CLUTCH SPRAG OUTER RACE

505 LOW CLUTCH SPRAG INNER RACE

Overdrive and Intermediate Clutch Assembly Legend480 OVERDRIVE CLUTCH BACKING PLATE

RETAINER RING (SELECTIVE)

481 OVERDRIVE CLUTCH BACKING PLATE

482 OVERDRIVE CLUTCH PLATE ASSEMBLY(INNER SPLINE)

483 OVERDRIVE CLUTCH PLATE ASSEMBLY(OUTER SPLINE)

484 OVERDRIVE CLUTCH SPACER

485 OVERDRIVE CLUTCH SPRING RETAINER RING

486 OVERDRIVE CLUTCH SPRING

487 OVERDRIVE CLUTCH PISTON ASSEMBLY

488 INTERMEDIATE CLUTCH BACKING PLATERETAINER RING (SELECTIVE)

489 INTERMEDIATE CLUTCH BACKING PLATE

490 INTERMEDIATE CLUTCH PLATE ASSEMBLY(INNER SPLINE)

491 INTERMEDIATE CLUTCH PLATE ASSEMBLY(OUTER SPLINE)

492 INTERMEDIATE CLUTCH APPLY PLATE

493 OVERDRIVE CLUTCH HOUSING

494 INTERMEDIATE CLUTCH SPRING

495 INTERMEDIATE CLUTCH PISTON ASSEMBLY

496 INTERMEDIATE CLUTCH (W/HOUSING ASSEMBLY)

497 INTERMEDIATE CLUTCH HOUSING RETAINER RING

Overdrive and Intermediate Clutch Assembly Legend

480 OVERDRIVE CLUTCH BACKING PLATE 96020178RETAINER RING (SELECTIVE)481 OVERDRIVE CLUTCH BACKING PLATE 96020211482 OVERDRIVE CLUTCH PLATE ASSEMBLY 96020209(INNER SPLINE)483 OVERDRIVE CLUTCH PLATE ASSEMBLY 96020210(OUTER SPLINE)484 OVERDRIVE CLUTCH SPACER 96020208485 OVERDRIVE CLUTCH SPRING RETAINER RING 96020857486 OVERDRIVE CLUTCH SPRING 96026036487 OVERDRIVE CLUTCH PISTON ASSEMBLY 96025338488 INTERMEDIATE CLUTCH BACKING PLATE 96020181/82/83/84/85/86/87/88RETAINER RING (SELECTIVE)489 INTERMEDIATE CLUTCH BACKING PLATE 96020686490 INTERMEDIATE CLUTCH PLATE ASSEMBLY 96024641(INNER SPLINE)491 INTERMEDIATE CLUTCH PLATE ASSEMBLY 96024642(OUTER SPLINE)492 INTERMEDIATE CLUTCH APPLY PLATE 96026074493 OVERDRIVE CLUTCH HOUSING494 INTERMEDIATE CLUTCH SPRING 96025392495 INTERMEDIATE CLUTCH PISTON ASSEMBLY 96020682496 INTERMEDIATE CLUTCH (W/HOUSING ASSEMBLY) 96020806497 INTERMEDIATE CLUTCH HOUSING RETAINER RING 96024192

Low Clutch Sprag Assembly

500 LOW CLUTCH ROLLER RETAINER 96026099501 LOW CLUTCH ROLLER THRUST WASHER 96022644502 LOW CLUTCH SPRAG ASSEMBLY RETAINER RINGS 96024631503 LOW CLUTCH SPRAG ASSEMBLY 96024631504 LOW CLUTCH SPRAG OUTER RACE 96024003505 LOW CLUTCH SPRAG INNER RACE 96023676

130

Center Support Assembly

Partlist_H

Figure 123

510

511

512

513

514

515

516

517

518519

520521 522

523

524525

526

527

528

529530

531

532533

534

535

5L40-EONLY

131

Center Support Assembly Legend510 LOW AND REVERSE CLUTCH PLATE

RETAINER RING (SELECTIVE)

511 LOW AND REVERSE CLUTCH BACKING PLATE

512 LOW AND REVERSE CLUTCH PLATE ASSEMBLY(INNER SPLINE)

513 LOW AND REVERSE CLUTCH PLATE ASSEMBLY(OUTER SPLINE)

514 LOW AND REVERSE CLUTCH APPLY PLATE

515 LOW AND REVERSE CLUTCH SPRING RETAINER RING

516 LOW AND REVERSE CLUTCH SPRING

517 LOW AND REVERSE CLUTCH PISTON

518 CENTER SUPPORT


520 2ND CLUTCH PISTON

521 2ND CLUTCH SPRING

522 2ND CLUTCH SPRING RETAINER RING

523 2ND CLUTCH APPLY PLATE

524 2ND CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

525 2ND CLUTCH PLATE ASSEMBLY (INNER SPLINE)

526 2ND CLUTCH BACKING PLATE

527 2ND CLUTCH BACKING PLATERETAINER RING (SELECTIVE)

528 2ND COAST CLUTCH PISTON ASSEMBLY

529 2ND COAST CLUTCH SPRING

530 2ND COAST CLUTCH SPRING RETAINER RING

531 2ND COAST CLUTCH SPACER

532 2ND COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

533 2ND COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE)

534 2ND COAST CLUTCH BACKING PLATE

535 2ND COAST CLUTCH PLATE (BACKING PLATE)RETAINER RING (SELECTIVE)

Center Support Assembly Legend

510 LOW AND REVERSE CLUTCH PLATE 96020578/79/80/81/82RETAINER RING (SELECTIVE)511 LOW AND REVERSE CLUTCH BACKING PLATE 96020781512 LOW AND REVERSE CLUTCH PLATE ASSEMBLY 96024392(INNER SPLINE)513 LOW AND REVERSE CLUTCH PLATE ASSEMBLY 96024391(OUTER SPLINE)514 LOW AND REVERSE CLUTCH APPLY PLATE 96026075515 LOW AND REVERSE CLUTCH SPRING RETAINER RING 96021039516 LOW AND REVERSE CLUTCH SPRING 96026035517 LOW AND REVERSE CLUTCH PISTON 96022480518 CENTER SUPPORT519 INPUT AND REACTION BEARING ASSEMBLY 96020152520 2ND CLUTCH PISTON 96024086521 2ND CLUTCH SPRING 96024261522 2ND CLUTCH SPRING RETAINER RING 96020062523 2ND CLUTCH APPLY PLATE 96024750524 2ND CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96023159525 2ND CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96023158526 2ND CLUTCH BACKING PLATE 96023155527 2ND CLUTCH BACKING PLATE 96023190/91/92/93/94/95RETAINER RING (SELECTIVE)528 2ND COAST CLUTCH PISTON ASSEMBLY 96025338529 2ND COAST CLUTCH SPRING 96026182530 2ND COAST CLUTCH SPRING RETAINER RING 96023196531 2ND COAST CLUTCH SPACER 96025916532 2ND COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE) 96024089533 2ND COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE) 96024087534 2ND COAST CLUTCH BACKING PLATE 96024914535 2ND COAST CLUTCH PLATE (BACKING PLATE) 96023180

132

Planetary Carrier Assembly

540 INPUT AND REACTION CARRIER OUTER RING


542 2ND CLUTCH ROLLER INNER RACE BEARINGASSEMBLY

543 2ND CLUTCH SPRAG RETAINER

544 2ND CLUTCH ROLLER OUTER RACE WASHER

545 2ND CLUTCH SPRAG OUTER RACE

546 2ND CLUTCH SPRAG ASSEMBLY RETAINER

547 2ND CLUTCH SPRAG ASSEMBLY


549 2ND CLUTCH SPRAG INNER (W/RACE)

550 REACTION INTERNAL GEAR

551 REACTION INTERNAL GEAR FLANGE WASHER

552 REACTION CARRIER BUSHING (2)

553 INPUT AND REACTION CARRIER


Partlist_J

Figure 124

540541

542543

544

548

549

550

551

552

552

553

553

554

545

546

546544

547

5L40-EONLY

4L40-EONLY

Planetary Carrier Assembly

540 INPUT AND REACTION CARRIER OUTER RING 96020059541 INPUT AND REACTION BEARING ASSEMBLY 96020142542 2ND CLUTCH ROLLER INNER RACE BEARING 96020141ASSEMBLY543 2ND CLUTCH SPRAG RETAINER 96026100544 2ND CLUTCH ROLLER OUTER RACE WASHER 96022643545 2ND CLUTCH SPRAG OUTER RACE 96022478546 2ND CLUTCH SPRAG ASSEMBLY RETAINER 96024630547 2ND CLUTCH SPRAG ASSEMBLY 96024630548 INPUT AND REACTION CARRIER BUSHING 96024902549 2ND CLUTCH SPRAG INNER (W/RACE) 96025114550 REACTION INTERNAL GEAR 96022882551 REACTION INTERNAL GEAR FLANGE WASHER 96022373552 REACTION CARRIER BUSHING (2) 96020084553 INPUT AND REACTION CARRIER 96024795554 INPUT AND REACTION BEARING ASSEMBLY 96020086

133

560

561564

562

563

560

561564

562

563

Figure 126

Rear Internal Gear Output Shaft Assembly (4L40-E)


Partlist_K4L40-E

Partlist_K

560 REAR INTERNAL GEAR


Figure 125

560 REAR INTERNAL GEAR


562 OUTPUT SHAFT ASSEMBLY

563 REAR INTERNAL RETAINER RING

564 CUP PLUG

562 OUTPUT SHAFT ASSEMBLY

563 REAR INTERNAL RETAINER RING

564 CUP PLUG


560 REAR INTERNAL GEAR 96024435561 INPUT AND REACTION CARRIER BUSHING 96020052562 OUTPUT SHAFT ASSEMBLY563 REAR INTERNAL RETAINER RING 96020058564 CUP PLUG 96020053562 OUTPUT SHAFT ASSEMBLY563 REAR INTERNAL RETAINER RING 96020058564 CUP PLUG 96020053


560 REAR INTERNAL GEAR 96024435561 INPUT AND REACTION CARRIER BUSHING 96020052560 REAR INTERNAL GEAR 96024435561 INPUT AND REACTION CARRIER BUSHING 96020052562 OUTPUT SHAFT ASSEMBLY563 REAR INTERNAL RETAINER RING 96020058564 CUP PLUG 96020053

134

Park Pawl Assembly A

600

615

601

602

613

604612

611

610

609608

607

614

605

606

600 MANUAL SHAFT DETENT LEVER

601 MANUAL SHAFT DETENT LEVER PIN

602 TRANSMISSION MANUAL SHIFT SHAFT SWITCHASSEMBLY

604 TRANSMISSION CASE ASSEMBLY


606 MANUAL SHIFT SHAFT

607 PARK PAWL ACTUATOR BRACKET


609 PARK PAWL ACTUATOR BRACKET BOLT

610 PARK PAWL SHAFT

611 PARK PAWL SPRING

612 PARK PAWL

613 PARK PAWL ACTUATOR ASSEMBLY

614 CUP PLUG

615 TRANSMISSION MANUAL SHIFT SHAFT ASSEMBLYSPACER

shift_assmA

Figure 127

135

Park Pawl Assembly B

600 601

602

613

603

604612

611

610

609608

607

605606

600 MANUAL SHAFT DETENT LEVER


602 TRANSMISSION MANUAL SHIFT SHAFT SWITCHASSEMBLY


604 TRANSMISSION CASE ASSEMBLY


606 MANUAL SHIFT SHAFT



609 PARK PAWL ACTUATOR BRACKET BOLT

610 PARK PAWL SHAFT

611 PARK PAWL SPRING

612 PARK PAWL

613 PARK PAWL ACTUATOR ASSEMBLY

shift_assmB

Figure 128

Park Pawl Assembly A

601 MANUAL SHAFT DETENT LEVER PIN 96020016602 TRANSMISSION MANUAL SHIFT SHAFT SWITCH 96025491ASSEMBLY604 TRANSMISSION CASE ASSEMBLY605 MANUAL SHIFT SHAFT SEAL 86447709606 MANUAL SHIFT SHAFT607 PARK PAWL ACTUATOR BRACKET 96024503608 PARK PAWL ACTUATOR BRACKET 96024504609 PARK PAWL ACTUATOR BRACKET BOLT 96020023610 PARK PAWL SHAFT 96020018611 PARK PAWL SPRING 96024306612 PARK PAWL 96024307613 PARK PAWL ACTUATOR ASSEMBLY 96025046614 CUP PLUG615 TRANSMISSION MANUAL SHIFT SHAFT ASSEMBLYSPACER

Park Pawl Assembly B

600 MANUAL SHAFT DETENT LEVER 96022578601 MANUAL SHAFT DETENT LEVER PIN 96020016602 TRANSMISSION MANUAL SHIFT SHAFT SWITCH 96025491ASSEMBLY603 MANUAL SHAFT DETENT LEVER PIN 96020016604 TRANSMISSION CASE ASSEMBLY605 MANUAL SHIFT SHAFT SEAL 8644709606 MANUAL SHIFT SHAFT607 PARK PAWL ACTUATOR BRACKET 96024503608 PARK PAWL ACTUATOR BRACKET 96024504609 PARK PAWL ACTUATOR BRACKET BOLT 96020023610 PARK PAWL SHAFT 96020018611 PARK PAWL SPRING 96024306612 PARK PAWL 96024307613 PARK PAWL ACTUATOR ASSEMBLY 96025046

136

BASIC SPECIFICATIONS

HYDRA-MATIC 4L40-E TRANSMISSION

HYDRA-MATIC 4L40-E(FOUR-SPEED)

Produced at: Strasbourg,France

Transmission DriveRear Wheel DriveAll Wheel Drive

Transmission Type4L40-E = 4: Four Speed

L: Longitudinal Mount40: Product SeriesE: Electronically Controlled

Automatic Overdrive with a Torque Converter Clutch Assembly.

Current Engine Range1.9 L Gasoline

Control SystemsShift Pattern (3) Two-way on/off solenoidsShift Quality Pressure Control Solenoid

Torque Converter Clutch Pulse Width Modulatedsolenoid control

Gear Ratios1st 2.822nd 1.543rd 1.004th 0.70Rev 2.38

Maximum Engine Torque180 Nm (133 lb ft)

Maximum Gearbox Torque430 Nm (317 lb ft)

Maximum Shift SpeedOutput: 8,500 RPM

Shift: 6,500 RPM

Maximum Gross Vehicle Weight3,500 kg (7,716 lb)

Transmission Fluid TypeDexron III

Transmission Fluid Capacity (Approximate)245 mm Converter (Dry): 8.5 L (9.0 qt)

Transmission Weight245 mm Converter (Dry): 66.5 kg (146.6 lb)

(Wet): 74.0 kg (163.1 lb)

Converter Sizes Available245 mm

Converter Bolt Circle DiametersFor 245 mm Converter 228.0 mm to 247.7 mm

Converter Stall Torque Ratio RangeFor 245 mm Converter 1.60 to 2.70

Converter K Factor RangeFor 245 mm Converter 122 to 260

Not all K Factors are applicable across the range of Converter Stall Torque Ratios.

Transmission Packaging Information*Overall Length

723.0 mm with 245 mm Converter(2 Wheel Drive)

*All dimensions shown are nominal.

Driver Shift Control Only

Pressure Taps AvailableLine Pressure

Information may vary with application. All information, illustrationsand specifications contained in this book are based on the latest productinformation available at the time of publication. The right is reserved tomake changes at any time without notice.

137

BASIC SPECIFICATIONS

HYDRA-MATIC 5L40-E TRANSMISSION

HYDRA-MATIC 5L40-E(FIVE-SPEED)

Produced at: Strasbourg,France

Transmission DriveRear Wheel DriveAll Wheel Drive

Transmission Type5L40-E = 5: Five Speed

L: Longitudinal Mount40: Product SeriesE: Electronically Controlled

Automatic Overdrive with a Torque Converter Clutch Assembly.

Current Engine Range2.2 L to 3.2 L Gasoline2.0 L to 3.0 L Diesel

Control SystemsShift Pattern (3) Two-way on/off solenoidsShift Quality Pressure Control Solenoid

Torque Converter Clutch Pulse Width Modulatedsolenoid control

Gear Ratios1st 3.422nd 2.213rd 1.604th 1.005th 0.75Rev 3.03

Maximum Engine Torque390 Nm (288 lb ft)

Maximum Gearbox Torque670 Nm (494 lb ft)

Maximum Shift SpeedOutput: 8,500 RPM

Shift: 6,500 RPM

Maximum Gross Vehicle Weight3,500 kg (7,716 lb)

Transmission Fluid TypeDexron III

Transmission Fluid Capacity (Approximate)245 mm Converter (Dry): 8.5 L (9.0 qt)

Transmission Weight245 mm Converter (Dry): 73.0 kg (161.0 lb)

(Wet): 80.5 kg (177.5 lb)

Converter Sizes Available245 mm245 mm Hybrid Converter (Option for applicationsabove approximately 280 Nm (207 lb ft)258 mm Converter (Option for applications aboveapproximately 350 Nm (258 lb ft)

Converter Bolt Circle DiametersFor 245 mm Converter 228.0 mm to 247.7 mmFor 245 mm Hybrid Converter 234.0 mm (Reference)For 258 mm Converter 234.0 mm (Reference)

Converter Stall Torque Ratio RangeFor 245 mm Converter 1.60 to 2.70For 245 mm Hybrid Converter 2.0 (Reference)For 258 mm Converter 1.60 to 2.10

Converter K Factor RangeFor 245 mm Converter 122 to 260For 245 mm Hybrid Converter 140 (Reference)For 258 mm Converter 106 to 164

Not all K Factors are applicable across the range of Converter Stall Torque Ratios.

Transmission Packaging Information*Overall Length

711.0 to 723.0 mm with 245 mm Converter(2 Wheel Drive)728.0 mm with 258 mm Converter(2 Wheel Drive)

*All dimensions shown are nominal.

Seven Position Quadrant or Driver Shift Control(P, R, N, D , 4, 3, 2)

Pressure Taps AvailableLine Pressure

Information may vary with application. All information, illustrationsand specifications contained in this book are based on the latest productinformation available at the time of publication. The right is reserved tomake changes at any time without notice.

138

HYDRA-MATIC 4L40-E

HYDRA-MATIC PRODUCT DESIGNATION SYSTEMThe product designation system used for all Hydra-matictransaxles and transmissions consists of a series of numbersand letters that correspond with the special features incorporatedin that product line. The first character is a number thatdesignates the number of forward gear ranges available in thatunit. For example: 4 = four forward gear ranges.

The second character is a letter that designates how the unit ismounted in the vehicle. When the letter T is used, itdesignates that the unit is transversely mounted and is usedprimarily for front wheel drive vehicles. The letter Ldesignates that it is longitudinally mounted in the vehicle andit is used primarily for rear wheel drive vehicles. The letterM designates that the unit is a manual transaxle ortransmission but not specific to a front or rear wheel drivevehicle application.

The third and fourth characters consists of a set of numbers,(i.e.40), that designate the transaxle or transmission Seriesnumber. This number signifies the relative torque capacity ofthe unit.

The fifth character designates the major features incorporatedinto this unit. For example, the letter E designates that theunit has electronic controls.

By using this method of classification, the HYDRA-MATIC4L40-E is a 4-speed, longitudinally mounted, 40 series unit,with electronic controls.

HYDRA-MATIC 4 L 40 E

Number of Type: Series: Major Features:Speeds: T - Transverse Based on E - Electronic Controls3 L - Longitudinal Relative A - All Wheel Drive4 M - Manual Torque HD - Heavy Duty5 CapacityV (CVT)

139

HYDRA-MATIC 5L40-E

HYDRA-MATIC PRODUCT DESIGNATION SYSTEMThe product designation system used for all Hydra-matictransaxles and transmissions consists of a series of numbersand letters that correspond with the special features incorporatedin that product line. The first character is a number thatdesignates the number of forward gear ranges available in thatunit. For example: 5 = five forward gear ranges.

The second character is a letter that designates how the unit ismounted in the vehicle. When the letter T is used, itdesignates that the unit is transversely mounted and is usedprimarily for front wheel drive vehicles. The letter Ldesignates that it is longitudinally mounted in the vehicle andit is used primarily for rear wheel drive vehicles. The letterM designates that the unit is a manual transaxle ortransmission but not specific to a front or rear wheel drivevehicle application.

The third and fourth characters consists of a set of numbers,(i.e.40), that designate the transaxle or transmission Seriesnumber. This number signifies the relative torque capacity ofthe unit.

The fifth character designates the major features incorporatedinto this unit. For example, the letter E designates that theunit has electronic controls.

By using this method of classification, the HYDRA-MATIC5L40-E is a 5-speed, longitudinally mounted, 40 series unit,with electronic controls.

HYDRA-MATIC 5 L 40 E

Number of Type: Series: Major Features:Speeds: T - Transverse Based on E - Electronic Controls3 L - Longitudinal Relative A - All Wheel Drive4 M - Manual Torque HD - Heavy Duty5 CapacityV (CVT)

140

GLOSSARY OF TECHNICAL TERMSAccumulator: A component of the transmission thatabsorbs hydraulic pressure during the apply of clutchor band. Accumulators are designed to control thequality of a shift from one gear range to another.

Adaptive Learning: Programming within the TCMthat automatically adjusts hydraulic pressures in orderto compensate for changes in the transmission (i.e.component wear).

Applied: An apply component that is holding anothercomponent to which it is splined or assembled with.Also referred to as engaged.

Apply Components: Hydraulically operated clutches,servos, bands, and mechanical one-way roller or spragclutches that drive or hold members of a planetarygear set.

Apply Plate: A steel clutch plate in a clutch packlocated next to the (apply) piston.

Backing Plate: A steel plate in a clutch pack that isusually the last plate in that clutch assembly (farthestfrom the clutch piston).

Ball Check Valve: A spherical hydraulically controlledcomponent (usually made of steel) that either seals oropens fluid circuits. It is also referred to as a checkvalve or checkball.

Band: An apply component that consists of a flexiblestrip of steel and friction material that wraps around adrum. When applied, it tightens around the drum andprevents the drum from rotating.

Brake Switch: An electrical device that providessignals to the Transmission Control Module (TCM)based on the position of the brake pedal. The TCMuses this information to apply or release the torqueconverter clutch (TCC).

Centrifugal Force: A force that is imparted on anobject (due to rotation) that increases as that objectmoves further away from a center/point of rotation.

Clutch Pack: An assembly of components generallyconsisting of clutch plates, an apply plate and abacking plate.

Clutch Plate: A hydraulically activated componentthat has two basic designs: (1) all steel, or (2) a steelcore with friction material bonded to one or two sidesof the plate.

Component: Any physical part of the transmission.

Control Valve Body: A machined metal casting thatcontains valve trains and other hydraulically controlledcomponents that shift the transmission.

Coupling Speed: The speed at which a vehicle istraveling and no longer requires torque multiplicationthrough the torque converter. At this point the statorfree wheels to allow fluid leaving the turbine to flowdirectly to the pump. (See torque converter)

De-energize(d): To interrupt the electrical current thatflows to an electronically controlled device making itelectrically inoperable.

Direct Drive: A condition in a gear set where theinput speed and input torque equals the output speedand torque. The gear ratio through the gear set is 1:1.

Downshift: A change in a gear ratio where inputspeed and torque increases.

Driver Shift Control: A selector system variant whichis configured to be shifted only manually, and allows forengine braking in first, second, third and fourth gears.

Duty Cycle: In reference to an electronically controlledsolenoid, it is the amount of time (expressed as apercentage) that current flows through the solenoid coil.

Engine Control Module (ECM): An electronic devicethat manages the electrical system of the engine.

Energize(d): To supply a current to an electronicallycontrolled device enabling it to perform its designedfunction.

Engine Compression Braking: A condition wherecompression from the engine is used with thetransmission to decrease vehicle speed. Braking(slowing of the vehicle) occurs when a lower gear ratiois manually selected by moving the gear selector lever.

Exhaust: The release of fluid pressure from a hydrauliccircuit. (The words exhausts and exhausting are alsoused and have the same intended meaning.)

Fluid: Generally considered a liquid or gas. In thispublication fluid refers primarily to transmission fluid.Fluid Pressure: A pressure (in this textbook usuallytransmission fluid) that is consistent throughout its circuit.

Force: A measurable effort that is exerted on an object(component).

Freewheeling: A condition where power is lost througha driving or holding device (i.e. roller or sprag clutches).

Friction Material: A heat and wear resistant fibrousmaterial bonded to clutch plates and bands.

Gear: A round, toothed device that is used fortransmitting torque through other components.

Gear Range: A specific speed to torque ratio atwhich the transmission is operating (i.e. 1st gear,2nd gear etc.).

141

GLOSSARY OF TECHNICAL TERMSGear Ratio: Revolutions of an input gear as comparedto the revolutions of an output gear. It can also beexpressed as the number of teeth on a gear as comparedto the number of teeth on a gear that it is in mesh with.

Hydraulic Circuit: A fluid passage which oftenincludes the mechanical components in that circuitdesigned to perform a specific function.

Input: A starting point for torque, revolutions or energyinto another component of the transmission.

Internal Gear: The outermost member of a gear setthat has gear teeth in constant mesh with planetarypinion gears of the gear set.

Internal Leak: Loss of fluid pressure in a hydrauliccircuit.

Land (Valve Land): The larger diameters of a spoolvalve that contact the valve bore or bushing.

Line Pressure: The main fluid pressure in a hydraulicsystem created by the pump and pressure regulatorvalve.

Manual Valve: A spool valve that distributes fluid tovarious hydraulic circuits and is mechanically linkedto the gear selector lever.

Orifice: A restricting device (usually a hole in thespacer plate) for controlling pressure build up intoanother circuit.

Overdrive: An operating condition in the gear setallowing output speed to be higher than input speedand output torque to be lower than input torque.

Overrunning: The function of a one-way mechanicalclutch that allows the clutch to freewheel during certainoperating conditions of the transmission.

Pinion Gear: A small toothed gear that meshes with alarger gear.

Planet Pinion Gears: Pinion gears (housed in a carrier)that are in constant mesh with a circumferential internalgear and centralized sun gear.

Planetary Gear Set: An assembly of gears that consistsof an internal gear, planet pinion gears with a carrier,and a sun gear.

Powertrain Control Module (PCM): An electronicdevice that manages most of the electrical systemsthroughout the vehicle.

Pressure: A measurable force that is exerted on anarea and expressed as kilopascals (kPa) or pounds persquare inch (psi).

Pulse Width Modulated (PWM): An electronic signalthat continuously cycles the ON and OFF time of adevice (such as a solenoid) while varying the amountof ON time.

Race (Inner or Outer): A highly polished steel surfacethat contacts bearings or sprag or roller elements.

Reduction (Gear Reduction): An operating conditionin the gear set allowing output speed to be lowerthan input speed and output torque to be higher thaninput torque.

Residual Fluid Pressure: Excess pressure containedwithin an area after the supply pressure has beenterminated.

Roller Clutch: A mechanical clutch (holding device)consisting of roller bearings assembled between innerand outer races.

Safety Mode: A condition whereby a component (i.e.engine or transmission) will partially function even ifits electrical system is disabled.

Servo: A spring loaded device consisting of a pistonin a bore that is operated (stroked) by hydraulic pressureto apply or release a band.

Solenoid Valve: An electronic device used to controltransmission shift patterns or regulate fluid pressure.

Spool Valve: A cylindrical hydraulic control devicehaving a variety of land and valley diameters, used tocontrol fluid flow.

Sprag Clutch: A mechanical clutch (holding device)consisting of figure eight like elements assembledbetween inner and outer races.

Throttle Position: The travel of the throttle plate thatis expressed in percentages and measured by the throttleposition (TP) sensor.

Torque: A measurable twisting force expressed interms of Newton-meters (Nm), pounds feet (lbs ft) orpounds inches (lbs in).

Torque Converter: A component of an automatictransmission, (attached to the engine flywheel) thattransfers torque from the engine to the transmissionthrough a fluid coupling.

Transmission Control Module (TCM): An electronicdevice that manages the electrical system of thetransmission.

Variable Capacity Pump: The device that providesfluid for operating the hydraulic circuits in thetransmission. The amount of fluid supplied variesdepending on vehicle operating conditions.

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5L40E Parts

Documents

clutch piston528

clutch sprag assembly548

reverse clutch piston520

reaction bearing assembly542

reaction carrier bushing400

transmission filter

transmissions drive

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