Volume 6, Issue 2 / Second Quarter, 2000 from

Larger Turbine Shaft O-Ring Added to 4L60E1998-up Camaro and Firebird models

with the LS1 aluminum V-8 engine and

the new generation Silverado and

Sierra now use a larger O-ring for the

turbine shaft. TransTec #17859 (OE

#24212987), which is reddish brown in

color, will be added to all 4L60E

gasket sets and overhaul kits with a

date code of BOO or later.Turbine Shaft

TransTec #17859 OE#24212987

Turbine Shaft O-Ring

Input Housing

Since April of 1999, all TransTecgasket sets and overhaul kits have con-tained an updated seal for the direct (front)clutch in the A518/46 and 47RH/RL.

This seal, with its wider base,compensates for a groove that haspossibly been machined incorrectlyfrom the factory. It has been proven inextensive field testing to correct “delayin reverse,” “slipping 2-3,” and “no 2-3”complaints.

TransTec #28313 is made of viton toresist wear and heat deterioration. AllTransTec kits with a date code of E99or later contain the new part.

Updated Clutch Sealfor A518/46 & 47RH/RL

.170”1989-UP

UPDATE SEALTransTec #28313

Machined Lip Seal

.130”1989-UP

O.E. #3410226TransTec #28023Molded Lip Seal

Base Dimension

VehicleHarness SealAdded to A606/42LE

TransTec is pleased to announce theaddition of the Vehicle Harness to caseseal for the 1993-up Chrysler A606 &42LE automatic transaxles.

TransTec’s new seal #32795 willbe included in all gasket sets andoverhaul kits with a date code of C99or later. Designed to keep dirt andother contaminants out and transmis-sion fluid in, this seal should be anintegral part of any transaxle repairoperation.

In This Issue...• Our Troubleshooter article

provides insight into Ford 4F27E

and Mazda FN4A-EL transaxles.

See Page 3.

• Wider base direct clutch seal

added to A518/46 and 47RH/RL.

See cover article.

• Larger turbine shaft O-ring addedto 4L60 gasket sets and overhaulkits. See cover article.

• Vehicle harness to case seal addedto gasket sets and overhaul kits for1993 Chrysler A606 and 42LEtransaxles. See cover article.

• 1994 Volkswagen/Audi clutchdesigns make a difference wheninstalling piston kits. See page 6.

• New extension housing sealavailable for Nissan RE4R01A.See back cover.

2

Ford 4F27E and Mazda FN4A-ELFront Wheel Drive 4-Speed Transaxle

TROUBLESHOOTER

3

Tony Darr, TransTec Transmission Technician

A couple go through a period oftime during their courtship when eachhas their own thoughts, opinions,choices and decisions. The balance ofthe relationship usually depends onhow the second party reacts to what thefirst party has done or is preparing todo. Disagreements, concessions,cooperation, understanding andforgiveness are all required to make alasting endeavor. Now,the two parties decide tomake this final,forever...a marriage.Plans are made, dates areset, bachelor andbachelorette parties arearranged and the wheelsare set in motion. For thegirls it doesn’t end there.They all get together andcollect things to bringthe new couple manyyears of good luck andprosperity. Somethingold, something new,something borrowed and somethingblue are gathered for the bride to wear,hold or otherwise adorn her person and/or her surroundings. The ceremony isperformed, vows and tokens of endear-ment are exchanged and a party is thrownto celebrate the two becoming one.

Well, the courtship between FordMotor Company and Mazda has beenlong and sometimes turbulent yet thetwo are still together. Jatco’s, CD4E’s,G4’s, F4’s A4LD’s, the late model4R44 and 55E’s and even the 5R55E’shave all been mixed and mingledbetween the two makes. Sometimes

only the brand monikers are left toidentify the two different vehicles. Itseems now that Ford and Mazda havecome to that point in their relationshipthat the decisions and choices are beingmade by one rather than two. This newtransaxle is a case in point. Beingreferred to as the 4F27E by Ford,FN4A-EL by Mazda and simply the“FN” by the engineering staff. It is a

joint venture of Ford andMazda to create a frontwheel drive four-speedtransaxle for the 1999Protege and the 2000Focus.

Something Old...

Four forward speeds,a reverse gear and anelectronically controlledconverter clutch, do notseem to make this unitdeviate too far fromtoday’s norm. Fullyelectronic controlled shift

patterns with a manual O/D canceloption, a hydraulic fail-safe of Park,Reverse, Neutral and Third gear are allstandard fair on this unit. Two sets ofcompound planetaries for the gear train,with the output carrier/input ring gearsplined to the primary final drive gear.This in turn is meshed with a transfergear and that is then meshed with thering gear of the differential. Fourmultiple disk clutch packs - Reverse, 3-4,Forward and Low/Reverse - a singlewrap band for second & fourth and asprag/one way clutch for low &reverse. Looks pretty complicatedto do, wink, wink.

Something New...

Here’s where the path gets a littledark and mysterious. No separatepiston lip seals are to be found here. Allthe pistons are of the bonded lip typeand guess what... Freudenberg-NOK orNOK of Japan make them all! OK, OKthat’s not entirely true, Chicago Raw-hide does make the Low Reverse piston.The servo piston, ALL the PLASTICsealing rings, valve body gaskets and,get this, the pressure control solenoidare all produced by FNGP/NOK in oneform or another.

There are six solenoids mounted onthe solenoid body, one EPC, two On/Offtypes and three PWM solenoids.Something really new about the elec-tronics of this unit is that the PCM nowsends the power signal to the solenoidrather than the ground. Just somethingto remember when getting out your testlight and jumper wires! The PWMsolenoids act directly upon the appliedelements and regulate the feel of eachshift. After the shift has occurred, thePCM strategy for the solenoids changesto a simple On/Off operation.

The two On/Off solenoids combinefor TCC operation. They also combinefor changing the source of fluid feedingthe forward clutch during TCC opera-tion. Without a hydraulic diagramavailable, this IS hard to understand.

The valve body assemblies are theeasiest of all. A three-tier set up; thelower body, which contains only threevalves, the center has only six and theupper only houses the shift solenoids.That’s only nine valves total with the

It seems now that

Ford and Mazda

have come to that

point in their

relationship that

the decisions and

choices are being

made by one

rather than two.

4

manual valve included. Plus, this is thefirst valve body assembly by Ford orMazda with no checkballs, orifices,check valves or other restrictions.That’s right none, nada, zip, zilch somuch for that picture to take up space!

Something Borrowed...

Since this was a joint venturebetween Ford and Mazda there are afew items borrowed from each otherstransmission or transaxle designs. TheLow/Reverse clutch and hub assemblydesign is borrowed from the C-6/E4OD. The internal gear is part of thehub on the 4F27E. The Reverse/3-4clutch drum assembly bears a strikingresemblance to the F4A-EL and G4A-EL’s design. The Low/Reverse one -way clutch is of typical Ford design,however, it splines - not bolts - into thecase only one way to allow the lubepassages to line up. The pump is asimple lightweight gear type borrowedfrom...hmm; lightweight,simple...borrowed from Mazda. Noweven with all the design borrowinggoing on, each marquee has there ownindividualities. Mazda uses an O-ringon the pump while Ford uses a lathe cutseal. Ford uses metal cased axle sealswhile Mazda uses rubber cased seals.The Reverse piston for the Ford Focusis taller than the one used in the MazdaProtege.

Something Blue...

OK, here’s where I have to stretch ita little bit! The common ground wirefor the PWM solenoids “A” & “C” isblue, the connector for PWM solenoid“B” is blue, the ground wire for theEPC solenoid is blue, the Ford oval isstill blue and I will assume the Focusand the Protege both can be ordered inBLUE!

A) PWM solenoid “B”, brown & green wiresB) PWM solenoid “C”, blue & black wiresC) PWM solenoid “A”, blue & green wiresD) Pressure control solenoid (EPC), blue & orange wiresE) On/Off solenoid “D”, single white wireF) On/Off solenoid “E”, single purple wireG) Transmission fluid temp. Sensor, two yellow wires

A) Output speed sensorB) Ford applications - axle seal Mazda applications use a rubber-cased seal

A B

A) Input speed sensorB) Line fitting - to coolerC) Band anchor boltD) Line fitting - from coolerE) Manual lever position sensorF) Case connectorG) Line pressure tap

Solenoid body: On the top row are the PWMsolenoids - notice the three O-rings per unit.Bottom row, from the left, the two On/Offsolenoids and the EPC solenoid. The EPCsolenoid has only one O-ring while the othersrequire two. The separator plate gaskets aredifferent for the solenoid body. The screenedgasket goes between the body and the plate;the thin non-screened gasket goes betweenthe plate and the main valve body.

A) LubeB) ConverterC) LubeD) Forward. ClutchE) 2-4 Servo Release

Second and fourth servo assembly, showingalso the O-ring seal for the cover. Look closelyat your servo, you’ll see the “FN” logo!

F) 2-4 Servo ApplyG) Reverse ClutchH) 3-4 ClutchI) Low/Reverse Clutch

E

C

I

F

B D

A

G

H

A B

C

D

F

G

E

A

B

F

D

G

C

E

5

Remove the reverse drum assembly and findthe inner race of the one-way clutch splined tothe case. The splines are made so there isonly one way to install the race - with the lubeholes lined up!

The gear train is comprised of two compoundplanetary sets. From the left, rear carrier,front planet sun gear, front planet carrier/rear planet ring gear, rear planet ring gear -part of the reverse drum assembly.

Upper accumulator piston and springs for theservo apply. Lower, forward accumulatorpiston and springs. The servo accumulatorsprings are of the same height, while theforward outer spring is taller than the inner.

This is what you’ll find with the rear coverremoved. “A” shows the selective washer/bearing race. “B” is the 3-4 clutch sealingrings. “C” reverse clutch sealing rings. “D”2-4 band assembly. “E” O-ring seals for thefluid apply passages between the case andcover. PS, The sealing rings are made by NOKof Japan

E

A

DC

B

This is the mess you’ll find in the reverse/3-4clutch drum. Bonded pistons everywhere!The larger one to the right is the reverse, thesmaller two piece assembly is for 3-4. Thesun gear for the rear planetary is at the far leftand it lugs into the reverse/3-4 drum.

Once the drums are removed from the rearof the case, you will find the Low/Reverseclutch assembly, reverse hub and one-wayclutch. When viewed like this, the drum isallowed to rotate counter clockwise and islocked clockwise.

Once the forward drum is pulled out the clutchhub is left behind. “A” retained by a wireretaining clip on the front sun gear “B”, theforward clutch hub is a P.I.T.A. to remove!

A

B

Clean and simple! Gear type fluid pump andforward clutch sealing rings. That’s right,NOK makes the rings!

With the converter housing and the pumpremoved you can now see the forward clutchdrum and shaft.

Laura Nemeth, EditorRebuilder News is dedicated to providing current technical information to the automatictransmission rebuilder. Reader’s comments/suggestions are welcome. Write: Editor,Rebuilder News, 11617 State Route 13, Milan, Ohio 44846, or e-mail: ln@fngp.com. Allrights reserved. ©1999 Freudenberg-NOK General Partnership. Reproduction without priorwritten permission is prohibited.

NEWSREBUILDER

6

Forward clutch assembly. Guess what...More bonded pistons!

Main valve body, lower sectionA) Manual valveB) By-pass valve, plain spring - lightC) Solenoid valve, orange spring - heavy

Note the spring for the by-pass valve is thesame as “B”, “C”, & “D” of the main body.The solenoid valve is the same as the oneused in the main body; the springs aredifferent lengths.

A) Solenoid valve, steel, plain spring - heavyB) Third lock-up valve, plain spring - lightC) by-pass valve, plain spring - lightD) Third lock up valve, plain spring - light (This is not a misprint!)E) Accumulator valve and springF) Solenoid shift valve, yellow spring-mediumG) Regulator valve, green spring - mediumNotice that “B” & “D” are the same valve, “B.”“C.” & “D” use the same spring and that thesolenoid valve is the only steel valve here.

Main valve body, upper section.A) 2-4 servo apply fluid sealB) Low/reverse clutch feed seal

A

B

AB

CA B C D

E

GF

Mainvalve body

Volkswagen has two different K1(1st-3rd) clutch and K3 (4th) clutchassembly designs that make a differ-ence when ordering piston kits.

All information from Volkswagenshows the early design from 1990-94and the late design from 1995-up, butwe have received several field reportsthat show both the early and latedesigns were used in 1994.

To ensure receiving the correctpiston kit for a 1994 application, it isbest to know which design your unithas.

An illustration of both the earlyand late design of the K1 and K3clutch assemblies is provided to aid inidentification.

Use TransTec kit #4768 for the earlydesign and kit #4860 for the late design.

1994 Volkswagen/Audi Clutch Designs Make a Difference

4th Gear Clutch(K3) Early

SnapRing

Spring

SpringRetainer

Spring

Piston

K3ClutchHousing

SnapRing

1st-3rd Clutch(K1) Late

Snap Ring

MoldedSpringRetainer

SealingRings

Piston

K1ClutchHousing

Spring

TransTec Bonded Piston Kit #4768 TransTec Bonded Piston Kit #4860

1st-3rd Clutch(K1) Early

Snap Ring

K1 ClutchHousing

Spring

CushionRings

Piston

SealingRings

4th Gear Clutch(K3) Late

SnapRing

MoldedSpringRetainer

K3ClutchHousing

Piston

Spring

7

Au

tho

riz

ed

Fu

ll-L

ine

Dis

trib

uto

rs

A & Reds Transmission PartsWichita, KS Kansas City, MO

APD Transmission PartsAtlanta, GA Marietta, GARaleigh, NC Jackson, MSJacksonville, FL

ATC Distribution GroupHTPLouisville, KY Charlotte, NCGrand Rapids, MI Taylor, MI

King-O-MaticCalgary, AL Regina, SKMississauga, ON Vancouver, BCMontreal, PQ

MetranJericho, NY Philadelphia, PA

RPMPhoenix, AZ Van Nuys, CATucson, AZ Colorado Springs, COAzusa, CA Denver, COFresno, CA Las Vegas, NVLos Angeles, CA Albuquerque, NMSan Leandro, CA Portland, ORSacramento, CA Salt Lake City, UTSan Diego, CA Seattle, WASan Jose, CA Spokane, WARancho Cucamonga, CA

RepcoDallas, TX Orlando, FLHouston, TX San Antonio, TXAustin, TX

RPM/HTPAtlanta, GA Memphis, TNCreve Coeur, MO Nashville, TNKansas City, MO Norfolk, VASpringfield, MO

Trans MartDallas, TX Norfolk, VAFlorence, AL St. Louis, MOJacksonville, FL Forest Park, OH

TranzpartsHillside, IL Janesville, WI

ATG Auto Trans Group, Inc.Calgary, AB Edmonton, ABVancouver, BC

Aceomatic ReconOrange, CA Phoenix, AZEl Cajon, CA Kent, WASimi Valley, CA Pittsburgh, PASacramento, CA Upper Marlboro, MDSan Jose, CA Cincinnati, OHDenver, CO Shrewsbury, MALexington, NC

CaltransSun Valley, CA

D&E Automotive SalesHazel Park, MI Lincoln Park, MIGrand Rapids, MI Willoughby, OH

Dean TransmissionAgawam, MA Pennsauken, NJ

FatscoFairfield, NJ

Mid States Transmission PartsDavenport, IA

NatproLos Angeles, CA Concord, CALas Vegas, NV Phoenix, AZ

Oklahoma Transmission SupplyOklahoma City, OK Tulsa, OKDenver, CO

Transtar Cleveland, OHAddison, IL Mesquite, TXBensenville, IL Nashua, NHBirmingham, AL Sacramento, CACincinnati, OH Sarasota, FLDenver, CO St. Louis, MOEdison, NJ Spokane, WAHarahan, LA Tucker, GAHouston, TX VanNuys, CALindenhurst, NY Yauco, PRLivonia, MI

T.P.S. Texarkana, TXLittle Rock, AR Shreveport, LA

2150 St. Clair AvenueCleveland, Ohio 44114-4080

BULK RATEU.S. POSTAGE

PAIDCLEVELAND, OHIO

PERMIT NO. 1

Aftermarket Division

Tra

ns

Te

ch

nic

al

Bu

lle

tin

New Extension Housing Seal for Nissan RE4R01A(1999-Up Nissan Pathfinders with 2-Wheel Drive)

Address Service Requested

TransTec #29715OEM #31375-51X01

1999-up Nissan Pathfinders with 2-wheel drive

use a new extension housing seal. The seal

along with the bushing and drive shaft yoke

was made larger to accommodate more torque.

This seal will be offered in bulk only under

part number 29715 (OEM #31375-51X01).

This seal is made by NOK.

The same seal is used in the Lexus Q45

vehicle with an RE4R03A

transmission.