EXPERTEC TSB (377149A)

DIAGNOSIS

Page 7A-17A-21 through 7A-17A-24, Malfunction Code Diagnosis and Default Charts;

Specific engine designators changed in codes 21, 22, and 74, Column heading "Probable Cause" changed to "Code Setting Criteria",

Corrections made to the Code Setting Criteria for codes 39, 53, 58, 73, 75, and 85;

Corrections made to the Default Action Column for codes 39, 52, 53, 58, 68, 72, 73, 75, 86 and 87;

The word "inhibit" is changed to "no" in codes 21, 22, 28, 52, 53, 68, 71, 74, 75, 81 and 83;

"Soft Landing" is defined in code 75; and, Symbols are changed to words in codes 28, 37 and 38.

Page 7A-17A-57, 4L80-E/4L80-EHD Wiring Diagram

Wire colors updated and transmission component terminal designators corrected.

Page 7A-17A-58, 4L80-E/4L80-EHD Component Resistance Chart

Wire colors updated.

Page 7A-17-59, 4L80-E Transmission Pressure Switch Assembly Resistance Check

Added "Turn Engine Off", corrected reference for intermiftent condition and high/low resistance definition below chart.

UNIT REPAIR

Pages 7A-17B-36 and 7A-17B-37, Pump Assembly

Step #3; Pressure regulator (231) and Boost Valve Assembly (228) designators corrected. Illustration updated to show the Valve Bore Plug (232) for the Pressure Regulator (231) and the Boost Valve Assembly (228) changed to the same plug as the TCC Valve (233).

Page 7A-17B-38, Fig. 71, Measuring Pump Body Face to Gear Clearance Pump Driven Gear (204) and Pump Drive Gear (205) designators corrected on illustration.

Page 7A-17B-39, Fig. 73, Assembling Pump Body and Pump Cover

Pump body and cover alignment band tool designation (J 21368) added to illustration.

Page 7A-17B-52, Fig. 98, Installing Fourth Clutch Snap Ring and Fig. 99, Installing Gasket, Pump Cover to Case

Corrected illustrations to match titles.

DISASSEMBLE

1. Five bolts (220).
   CAUTION: Regulator spring (230) is tightly compressed. Use care when removing retaining ring (226). Personal injury could result.
2. Retaining ring (226).
3. Pressure regulator and boost valve assemblies (228 and 231).
4. Converter limit valve assembly, pin (.21 1), plug (212), spring (213) and valve (214).
5. Torque converter clutch enable valve assembly, sleeve (215), spring (216) and valve (217).
6. Torque converter clutch valve assembly, snap ring (221), plug (232), valve (223), spring (224), plug (225) and pin (211).
7. Inspect markings on gear faces and chamfer of gear teeth, before removing gears (204) and (205) from pump body, to ensure gears were installed correctly.
8. Pump drive gear (205) and driven gear (204).
9. Seal rings (219) and selective thrust washer (218).
10. Seal ring (5) pump to case.

INSPECT

1. Gear pockets, crescent, pump body face, and bushing for:
   • Scoring.
   • Nicks.
   • Wear.
2. Oil passages for:
   • Foreign material or debris.
   • Porosity.
   • Scored or irregular mating surfaces.
   • Cross channel leaks.
3. Pump body bolt threads for:
   • Damage.
4. Oil seal (201), bushing (202) for:
   • Wear.
   • Damage.

INSPECT

1. Pump gear face for:
   • Wear.
   • Scoring.
2. Stator shaft splines for:
   • Damage or stripped splines.
3. Stator shaft bushings (233) and (234) for:
   • Wear.
   • Galling.
4. Oil ring grooves for:
   • Nicks.
   • Burrs.
   • Debris.
5. Pressure regulator assembly, converter limit valve assembly, TCC enable valve assembly and TCC valve assembly for:
   • Free movement of valves in bores.
   • Chips.
   • Burrs.
   • Distortion.
   • Plugged oil passages.
6. Breather hole in pump cover blocked.

CLEAN

• All components.

MEASURE

• For proper gear clearance install pump gears (204 and 205) in body (203) as marked. Chamfer side down.
• Measure clearance between gears and body with straight edge and feeler gage.
• Maximum clearance 0.017 to 0.071 mm (0.0007 to 0.0028 inch.).
• Pump body with straight edge to insure flatness.

ASSEMBLE

1. Drive gear (205) and driven gear (204) with identification marks facing up. Outside diameter chamfer side down on gear teeth (Fig. 71).
   • Install driven gear (204) into body.
   • Lubricate drive gear (205) and driven gear (204) with DEXRON-IIE automatic transmission fluid.
   • Install drive gear into pump body (203) with flats facing up.
2. Pressure regulator valve (231) into bore.
3. Bore plug (232) and valve straight pin (211).
4. Springs (230 and 238) and retainer (229) in pressure regulator bore.
5. Regulator boost valve (228) into boost valve bushing (227), stem out against spring (230).
6. Snap ring (226).
7. Converter limit valve (214), spring (213), plug (212) and pin (211).
8. TCC enable valve (217), spring (216), compress spring down and insert a small rod into hole A (see figure 71) to hold down spring until sleeve (215) is installed. Pull out rod when sleeve is installed.
9. TCC valve plug (225), pin (21 1), load from other end of bore, spring (224), valve (223), plug (232) and snap ring (221).
10. Cover (206) on body (203).
11. Five bolts (220).
    • Finger tight only at this time.

ASSEMBLE

Fig.s 73 and 74

TOOLS REQUIRED

J 21368 Alignment Band

J 38739 Oil Pump Seal Ring Installer, Sizer and Pusher

J 25025-1 Guide Pins

J 37789 Pump - Install/Remove

1. J 21368 on pump assembly. J 25025-1 Guide pins in bolt hole.

TIGHTEN

• Five bolts (220) to 24 N-m (18 lb. ft.)
  1. Oil seal (5).
     NOTE: Coat the pump to case "O" ring seal (5) with TRANSJEL or petroleum jelly. This will ease drawing the pump into the case, and prevent seal damage.
  2. Correct selective thrust washer (218) as determined by Front End Play Check during disassembly. Use TRANSJEL J 36850 or equivalent to hold in place.
  3. Two solid oil seals (219). Using J 38739 installer pusher and sizing tool onto pump hub.

IMPORTANT

• Be sure to use small chamfer end of sizer J 38739 to do the lower ring.

Then use larger chamfered end to size other seal.

CLEAN

• All components.

INSPECT

1. Front servo piston (58) for:
   • Porosity or damage.
   • Seal and seal ring groove for damage.
2. Piston pin (55) for:
   • Wear.
3. Spring (60) for:
   • Distortion.
4. Servo bore for:
   • Wear or scofing.

ASSEMBLE

1. New seal (57) onto piston (58).
2. Front servo piston spring (60) and retainer (59).
3. Ring (56), piston pin (55) and piston (57).

DISASSEMBLE

• Retaining clip (64) from rear band apply pin (73) and inspect.

INSPECT

1. Rear Accumulator piston (68) and Rear Servo piston (65) for:
   • Porosity or damage.
   • Ring groove damage.
2. Seals (66, 67 and 69) for:
   • Nicks or cuts.
3. Cover (62) for:
   • Porosity.
   • Scored or damaged.
4. Springs (71 and 74) for:
   • Distortion.
   • Damage.
5. Pin (73) for wear.
6. Servo bore for wear or scoring.

CLEAN

• All components.

ASSEMBLE

1. Rear servo spring retainer (72), rear servo spring (71) and servo washer (70) on rear band apply pin (73).
2. Reverse servo piston seal (66) on rear servo piston (65) and press onto rear band apply pin (73).
3. Retaining ring (64).
4. Lube seals, inner (69) and outer (67) before installing accumulator piston seals on accumulator piston (68). Place in rear servo piston.

INSTALL OR CONNECT

1. Gasket (6) on transmission case (7) using guide pins J 25025-1 at 12 o'clock and 5 o'clock position.
2. Oil pump assembly (4) in transmission case (7) using J 37789, bolt holes closest together are towards channel face.
3. Seven bolts (3).

TIGHTEN

• Bolts (3) to 24 N-m (18 lb. ft.).

TOOLS REQUIRED

J 8001 Dial Indicator

J 38694 Pump Seal Installer

MEASURE

1. Install J 8001.
2. Eliminate slack by pressing down on turbine shaft (502) and with J 28585 up on output carrier. Then pull up with 3 to 5 lbs. of force on turbine shaft to eliminate any clearance between snap ring (522) and overdrive carrier (514).