Filed Under (Chevrolet) by admin on 30-12-2010
Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Condition Some customers may comment on a shudder condition at approximately 64-80 km/h (40-50 mph) when the TCC engages. Cause This condition may be caused by water in the automatic transmission fluid (ATF). Water may enter the transmission by dripping from the cowl area onto the handle of the transmission fluid level indicator. Indications of water in the ATF may include: • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. Correction First, repair the transmission and second, replace the transmission fill tube, seal and level indicator to prevent repeat water contamination of the ATF. Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: If water or coolant is found in the transmission, the following components MUST be replaced. • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow . Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube.
Filed Under (Toyota) by admin on 04-06-2011
Some customers may complain about a “squeak” or “creak” noise when depressing or releasing the clutch pedal. The clutch master cylinder clevis assembly has been improved to eliminate this condition. Repair Procedure 1. Record all radio presets before starting. 2. Disconnect the negative (–) battery terminal cable. 3. Remove the clutch pedal sub–assembly. A. Remove the front door opening trim LH (scuff plate). B. Remove the cowl side trim board. C. Remove the instrument panel finish panel lower No. 1. D. Remove the driver’s side Junction Block. E. Remove the turnover (compression) spring. F. Remove the bolt attached to the instrument panel reinforcement assembly. G. Remove the clutch pedal sub–assembly. a. Remove the bolt and nut. b. Remove the clutch pedal from the clutch pedal support. 4. Remove the clutch pedal spring holder from the clutch pedal support. 5. Remove the clutch pedal pad. 6. Remove the two (2) clutch pedal bushes from the clutch pedal. 7. Remove the clutch pedal shaft collar. 8. Using needle–nose pliers, remove the No. 1 cushion from the clutch pedal. 9. Install the clutch pedal No. 1 cushion on the NEW clutch pedal sub–assembly. NOTE: Install parts on the NEW clutch pedal sub–assembly BEFORE installing in the vehicle. 10. Install the clutch pedal shaft collar. A. Apply MP grease to the clutch pedal shaft collar. B. Install the clutch pedal shaft collar onto the clutch pedal. 11. Install the clutch pedal bushes. A. Apply MP grease to the two (2) NEW bushes. B. Install the two (2) bushes onto the clutch pedal. 12. Install the clutch pedal pad. 13. Install the clutch pedal spring holder. A. Apply MP grease to the contact surface of the clutch pedal spring holder. B. Install the clutch pedal spring holder. 14. Remove the clevis sub–assembly. A. Measure length “A” of the clutch master cylinder. a. Measure length “A” between the lock nut and the thread end with a ruler. b. Record length “A”. B. Remove the clevis sub–assembly from the master cylinder. a. Loosen the lock nut. b. Rotate and remove the clevis sub–assembly. 15. Install the NEW clevis sub–assembly. A. Rotate the lock nut to match length “A”. B. Rotate and install the NEW clevis sub–assembly to contact the lock nut. C. Tighten the lock nut and torque to specification. Torque: 11.8 NSm (120 kgfScm, 8.7 ftSlbf) D. Apply MP grease to the ball end of the clevis sub–assembly where it will contact the clutch pedal. 16. Install the NEW clutch pedal sub–assembly. A. Install the clutch pedal onto the clutch support with the bolt and nut. Torque: 34 NSm (347 kgfScm, 25 ftSlbf) HINT: Install the bolt from the left side of the vehicle. B. Apply MP grease to the clutch pedal sub–assembly where the clevis sub–assembly contacts the clutch pedal. NOTE: Failure to apply grease to the clevis and clutch pedal sub–assemblies could cause the noise to return. C. Tighten the bolt to the instrument panel reinforcement assembly. Torque: 8 NSm (82 kgfScm, 6 ftSlbf) 17. Install the turnover (compression) spring. A. Apply MP grease to the contact surface of the spring holder, clutch pedal, and spring. B. Install the spring onto the clutch pedal and spring holder.
Filed Under (Ford) by admin on 19-02-2011
NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new Oil-To-Air (OTA) transmission fluid cooler must also be installed. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service. NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service. The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission. A new Oil-To-Air (OTA) transmission fluid cooler must be installed under the following condition. For additional information, refer to Section 307-02. Evidence of broken transmission components or transmission fluid contamination found due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failure Sufficient component wear which results in metallic contamination 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Section 419-03. Failure to follow the instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to Fluid Pan, Gasket and Filter in this section. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. After transmission fluid has drained remove the bolts and the pan and drain the remaining transmission fluid that is in the pan. 4. Install the transmission fluid pan and the old transmission fluid pan gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 5. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.
Filed Under (Ford) by admin on 08-03-2011
Removal CAUTION: Remove the entire clutch hydraulic system from the vehicle as an assembly when installing a new clutch master cylinder assembly (7C522). 1. Disconnect the clutch hydraulic tube from the dash clip. 2. Raise and support the vehicle. For additional information, refer to Section 100-02. 3. Unlock and remove the slave cylinder (7A564) from the transmission. Compress and twist the slave cylinder to unlock it from the transmission. 4. Disconnect the clutch hydraulic tube from the floor pan clip. Position the slave cylinder and hydraulic tube forward below the left engine bank. This will make it easier to unlock the clutch master cylinder from the clutch pedal and support bracket (7B633) by reducing tension on the hydraulic tube. 5. Lower the vehicle. 6. WARNING: The clutch pedal is under spring tension. Unlock the push rod bushing retaining clips and separate the clutch master cylinder push rod from the clutch pedal. 7. Remove and discard the push rod bushing (7526). 8. Remove the switch cover, and remove the clutch pedal position switch (7C534) from the clutch master cylinder push rod. 9. Separate the power distribution box from the bracket to gain access to the clutch master cylinder. 10. Unlock and remove the clutch master cylinder from the clutch pedal and support bracket. Compress and twist the clutch master cylinder clockwise 45 degrees to unlock it from the clutch pedal and support bracket. 11. Remove the clutch hydraulic reservoir from the wiring tray and separate the clutch hydraulic tube from the brake master cylinder assembly. Position the clutch hydraulic reservoir aside. 12. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Remove the clutch hydraulic system from the vehicle. 13. Clean the clutch hydraulic system components to prevent contaminants from entering the hydraulic system. 14. CAUTION: Place a suitable container under the clutch master cylinder. Disconnect the hydraulic tube from the clutch master cylinder. 1. Using a 3/32-inch punch and a hammer, drive out the roll pin, and discard it. 2. Disconnect the hydraulic tube from the clutch master cylinder.
Filed Under (Subaru) by admin on 02-01-2011
It may seem obvious, but the first step in the job is to disconnect the battery after recording the customer’s radio station presets. Even a manual transmission has a surprising number of wires attached to and surrounding it. Why take the chance of damaging anything due to an accidental short circuit? Remove the resin ‘pitching stopper’ and its bracket on the transmission. This step is necessary for the engine and transmission to drop far enough to clear the firewall during transmission removal. A special tool (P/N 927670000) is available to support the engine once the transmission has been removed, but you can replace the clutch without this aid. Many manual transmission Subaru vehicles are also equipped with the Hill- Holder system. This system lets the driver remove his right foot from the brake pedal after applying the brakes to stop on an incline of more than three degrees. This prevents ‘rollback’ when engaging the clutch to move the vehicle forward on a hill. The Hill-Holder cable shown here below the conventional clutch cable links the clutch pedal to the Hill-Holder pressure hold valve (PHV). Loosen both cables and remove their bracket from the transmission. Several electrical connectors are located at the top right side of the transmission (neutral position switch, back-up light switch, speed sensor, etc.). The connectors are color-coded, so it’s a simple matter to disconnect them and move them aside. Also remove the upper transmission mounting bolts, assorted brackets, main battery ground cable and the starter motor at this time. This transmission ground cable can easily escape notice. The other end of the cable is unreachable from above the transmission. A transmission case bolt must be removed to remove the ground wire at the transmission, so removing it at the body makes more sense to avoid the risk of a leak. Position the cable out of the way so it doesn’t snag on anything during transmission removal.