JR403E - Slips In 2nd, 3rd, 4th Gear And/Or No Upshifts, Or Falls Out Of 4th Hot

COMPLAINT: Before and/or after rebuild, the vehicle exhibits a slipping condition in 2nd, 3rd, or 4th, and/or a no upshift condition, or falls out of 4th gear when “Hot“.Get more obd2 scanner for help.

CAUSE: The cause may be, the bolts that retain the servo assembly to the main case were fractured and allowed the servo assembly to fall out of it’s bore and to rest on the oil pan. This action could result in “Major” pressure losses to the servo and could cause an alignment problem with the servo pin and the O.D. servo piston causing it to possibly crack (See Figure 1).

CORRECTION: There is now available from Isuzu, Grade 9 servo retaining bolts to replace the previous Grade 7 retaining bolts, and should be replaced on every JR403-E transmission regardless of the vehicle in which it is found. They are available under Isuzu part number 8-97 107-000-0. Check and replace the overdrive servo piston as necessary (See Figure 1).

SERVICE INFORMATION:
Servo Retaining Bolts (Isuzu  Part No.) .......................................................... 8-97107-000-0
Overdrive Servo Piston (Isuzu Part No.) ................................................................. 97039481

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SATURN - New Design Solenoids

COMPLAINT: After the replacement of new actuators (solenoids) on the valve body, the vehicle displays a very erratic shift pattern. Codes for the solenoids may or may not be set. Get more obd2 scanner from vtoolshop.com.

CAUSE: The cause may be, the wrong design level of actuators installed during rebuild. All 1991 and 1992 design level solenoids measure approximately 2.5 - 4.5 ohms resistance, while 1993 and Up solenoids measure approximately 4.0 - 6.0 ohms resistance. These actuators (solenoids) will not interchange. (See Figure 3)

CORRECTION:
Install the correct design level solenoids. You can verify the solenoid resistance through the transmission connector located in the top pan, using a DVOM set to ohms. Refer to Figure 1 for a view of the actuator connector with each terminal identified. Each actuator has it's own positive and negative terminal as shown in Figure 1. As you are checking each actuator, refer to the chart in Figure 2 for resistance values.

Note: The chart in Figure 2 provides the acceptable resistance values based on temperature and the year of the vehicle. All actuators should be within 1 ohm of each other. Also Saturn color coded the actuators as well, to assist in preventing the wrong design level actuators being installed. BLACK or BLUE ends on the Actuators are 1991 and 1992 design level for 91-92 vehicles only. The 1993-Up design level Actuators have a RED end and are for 93-Up vehicles only, as shown in Figure 3.

SERVICE INFORMATION:
Actuator (Solenoid) 1st Design (Black or Blue)......................................................21002248
Actuator (Solenoid) 2nd Design (Red)....................................................................21002509

Figure 1: http://flic.kr/p/dXYoK5
Figure 2: http://flic.kr/p/dXSHJr
Figure 3: http://flic.kr/p/dXYoKQ
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THM 4T60-E - Transaxle Case Seal Pocket Change & New 1-2 Servo Seal

CHANGE: Beginning on February 20, 1995, approximately half way through the 1995 model year, all THM 4T60-E transaxles were built using a new design 2-1 servo square cut seal, which also required a deeper seal pocket in the transaxle case (See Figure 1). Since this was implemented as a running change about half of the 95 models will require the previous seal and the other half will require the new design seal. You also can find useful car tools like maxscan gs500 and MINI ELM327 Bluetooth from vtoolshop.com to know more.

REASON: Developed to improve the assembly process.

PARTS AFFECTED:
(1)  2-l SERVO “SQUARE CUT” SEAL - New design square cut seal was made twice as tall as the previous design seal. The new design square cut seal measures .132” tall, and the previous design measures .066” tall, as shown in Figure 1. The wall thickness and seal diameter did not change. This seal retains drive oil in the forward servo circuit to apply the forward band.

(2) TRANSAXLE CASE  - The seal pocket in the case was machined deeper to accommodate the new design square cut seal. The new design seal pocket measures .112” deep, and the previous design seal pocket measures .054” deep, as shown in Figure 1.

NOTE: The new design square cut seal is not currently included in ail gasket packages, but is available separately under OEM service package part number 24204817, which will get you both design seals.

INTERCHANGEABILITY:
The 2-l servo square cut seals are not interchangeable.
Previous design seal must be used in .054” deep case pocket. New design seal must be used in .112” deep cave pocket.

SERVCE INFORMATION:
2-l Servo Square Cut Seal Package (Includes Both Seals) .......................................24204817

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THM 4T60-E - Tie-Up In Park And Reverse Moves Forward In Neutral Tie-Up On 2-3 Upshift

COMPLAINT: After rebuild, the vehicle displays a tie-up condition (In Gear) while the selector lever is in the Park position, a tie-up condition in Reverse, moves forward in Neutral, and a tie-up condition on the 2-3 shift. Get more hot tools vag tacho usb and xprog m that are useful.

CAUSE: The cause may be, the. rear lube pipe and  the apply pipe for the 2-l manual servo, reversed in the accumulator housing cover (See Figure 1). This will allow lube oil to apply the 2-l manual servo and the band as soon as the engine is started.

CORRECTION: Install the tubes into the accumulator housing cover with the 2-l manual servo apply pipe in the “Center” hole, as shown in Figure 2, and the rear lube pipe in the right hand hole, as shown in Figure 2. The forward servo apply pipe cannot be installed in the wrong hole as it is a larger diameter than the other two.

NOTE:
Figure 1 shows the ‘incorrect” assembly of the pipes.
Figure 2 shows the “Correct” assembly of the pipes.
http://www.autobd.info/ 

  

FORD AODE/4R70W - Checkball Locations Change For 1996-Up Models

CHANGE: Beginning in the 1996 model year Ford Motor Company changed the checkball locations in the main valve body on AODE/4R70W transmissions. The Number 1 checkball in the 1992-1995 models was eliminated, the location was moved and the ball was re-numbered as the Number 9 checkball car diagnostic tool.

REASON: Improved 4-3 and 4-2 downshifts.

PARTS AFFECTED:
(1)VALVE BODY CASTING - Worm track configuration changed to accommodate the new checkball locations.
(2)SPACER PLATE - Hole configuration changes to accommodate the changes in the new checkball locations.
(3)VALVE BODY TO SPACER PLATE GASKET - Hole configuration changes to accommodate the new checkball locations and OEM part numbers are listed below.
(4)SPACER PLATE TO CASE GASKET - Hole configuration changes to accommodate the new checkball locations and OEM part numbers are listed below.

INTERCHANGEABILITY:
None of the parts listed above will interchange with previous design level parts. You can use all of the parts listed above as a package to back service previous models as long as calibration concerns are addressed and using the proper size valve body pilot bolts and/or case sleeves to ensure proper valve body alignment.
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SERVICE INFORMATION:
Valve Body to Spacer Plate Gasket (92-95 Models) ...........................................F2VY-7D100-A
Spacer Plate to Case Gasket (92-95 Models) ......................................................F2VY-7C155-A
Valve Body to Spacer Plate Gasket (96-Up Models) ...........................................F7AZ-7D100-AA
Spacer Plate to Case Gasket (96-Up Models) ......................................................F7AZ-7C155-AA
Valve Body Cover Plate Gasket (92-95 Models) .................................................F2VY-7H173-A
Valve Body Cover Plate Gasket (96-Up Models) ................................................F6AZ-7H173-A

MAZDA/FORD G4A-EL - 3rd Gear Shift Shuttle

COMPLAINT: Vehicles equipped with G4A-EL transmissions may exhibit a hunting sensation or shift shuttle, between the speeds of 25-35 mph. This sensation normally happens, while in 3rd gear, right before the 3-4 shift.

CAUSE: The cause may be, the 3-4 shift solenoid is partially stuck open, the 3-4 shift solenoid "O-ring" is damaged or the 3-4 shift valve bore plug is leaking. This may cause the 3-4 shift valve to block Coast Clutch apply oil and to exhaust Servo Release oil. Computer strategy, while in 3rd gear under 25MPH., commands the 1-2 solenoid off which in turn blocks Servo apply oil.
At speeds above 25MPH., while in 3rd gear, computer strategy commands the 1-2 solenoid to be on which turns on Servo apply pressure in preparation for the upshift to 4th gear. When 1-2 solenoid application occurs, while in 3rd gear above 25 MPH., drum speed or pulse generator output may drop because of the lack of Servo Release oil. When the computer recognizes that Pulse Generator input or drum speed has dropped it may turn the 1-2 solenoid off. This on and off cycling of the 1-2 solenoid may continue until the upshift to 4th occurs.
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CORRECTION: Refer to Figure 1 to identiy the 3-4 shift solenoid placement and to check it's mechanical function. Apply air pressure to the end of the solenoid as shown in Figure 1 to ensure that the 3-4 shift solenoid is closed and check the O-ring for damage. With the 3-4 solenoid removed, air check the 3-4 shift valve through the hole where the 3-4 solenoid is placed and ensure that there is no air leakage from the bore plug. Refer to Figure 2 for 3-4 shift valve and bore plug location.

Precautions about original launch CNC 602A

This article is all about essential information about using launch cnc602A and troubleshooting.
Parts list of the main unit:
Item Part No. Part name Item Part No. Part name
1 X103200209 Shaft for cover 8 X103200218 Cabinet
2 X103200214 Back baffle 9 General standard part
Cross bulged screw with gasket
3 X103010153 Cross bulged screw with gasket 10 General standard part Rubber gasket
4 X103200213 Dustproof cover for power socket 11 X103200576 Left side board
5 X103010111 Cross recessed screw 12 X103200217 Backlight cover
6 X103200210 Panel 13 X103240196 Fuel tank
7 X103200208 Right side board 14 X103200113 Cover for fuel filling port
Parts list of the fuel path :
Item Part No. Part name Item Part No. Part name
1 103250008 Knurled screw 2 18 Z205010084 Control board（PCA）
2 103250006 Screw for press plate 19 Z205010263 Drive board（PCA）
3 103250005 Crescent press plate 20 103010039 Screw M4x10
4 103250028 Stopper for distributor 21 103240026
Hexagonal copper screw, M3 x
15
5 104130026 O-ring,ф27×2.45 22 103010022 Screw, GB818-85 M3×6
6 104130023 O-ring,ф20×2.65 23 104130016 Upper O-ring，φ40.2×22×3
7 104130030 O-ring,ф7.1×2.65 24 104110009 Glass tube
8 103250013 Top-supply connector 1 25 103200350 Inner hexagonal thread sleeve
9
Top-supply injector (is not
included in materials for unit)
26 104130017 Lower O-ring, φ40.2×15×3
10 103250002 6-cylinder distributor 27 X103040012 Flat gasket
11 103010158
Cross bulged screw,
M5×20
28 102240003 Solenoid valve
12 103250019 Support screw 29 103240015 Tower connector
13 103030050 Hexagonal nut, M5 30 103200053 Clamp, 6-12
14 103250003 6-cylinder upper plate 31 X103200019 Leading fuel hose for fuel tank
15 103010148 Screw M3×8 32 103250004 6-cylinder lower seat plate
16 107040041 Film 33 103040011 Gasket
17 X103200210 Control panel 34 103030050 Nut, M5
Item Part No. Part name Item Part No. Part name
35 105020085 Navigator connector cable 44 103160021 Overflow valve
36 104120026 Fuel return hose, PU 5×8mm 45 104130029 O-ringφ4.87×1.8
37 104130030 O-ringφ7.1×2.65 46 103200355 Connector assembly
38 103240015 Tower connector 47 X103040103 Flat gasket
39 103200053 Clamp 48 103030050 Hexangular nut,M5
40 104130086 Durable hose 49 202010019 Quick connection hose
41 103260003 Gasoline filter 50 103110124 Screw, M4×12
42 103200212 T-type block 51 103200357 Cabinet
43 103240050 Quick connector( male) 52 102990021 Backlight, AC 220V/8W
Parts list of fuel distributor:
Item Part No. Part name Item Part No. Part name
1 103250002 6-cylinder fuel distributor 7 103240050 Quick connector
2 202010019 Quick connection hose 8 103160021 Overflow valve
3 103250003 Upper plate 9 103260003 Gasoline filter
4 103250004 Lower plate 10 104120026
Return fuel viewer for on-vehicle
cleaning
5 103240050 Quick connector (male) 11 103240195 Copper hose, Φ2.5
6 103240015 Tower connector
Item Parts No. Parts Name Number Specifications Remarks
1 201020068
CNC-601A Fuel
distributor package
1 set
For the Installation and
fixation of injector
2 103250002
CNC-601A Fuel
distributor
1
Distributing the fuel from
the quick connector to
each injector
3 103250005 Crescent plate 3
Tightening the fuel
distributor stopper
4 103250006 Press plate bolt 3
Tightening the fuel
distributor assembly
5 103250014
Adaptor 2 for fuel
top-supply injector
6
For some top-supply
injectors
6 103250028
Stopper for fuel
distributor
6
Installation of various of
top-supply injectors and
accessories
7 103230106
Adjusting pole 1 for
reverse flush
2 Length：40mm
8 103250007 Knurled nut 2
Installation between the
fuel distributor assembly
and upper press plate.
9 103250008 Pressing screw 2 2
Tightening the fuel
distributor assembly
10 103250013
Adaptor 1 for fuel
top-supply injector
6 Bore: Φ10.5
11 103250015
Swiss thread adaptor
for fuel top-supply
injector
6
Be used for connecting
swiss thread injector
(M10×1).
12 103250016
Coarse thread adaptor
for fuel top-supply
injector
6
Be used for connecting
coarse thread injector
( M12).
13 104990012 BUICK injector adaptor 6
Be used for the connection
of BUICK injector.
14 103250018 Hexangular stopper 5
Be used when the amount
of injectors is less than 6. 15 105020217
CNC pulse signal
connection cable 1
10
Be used for the connection
of special injector, T=0.5
16 105020218
CNC pulse signal
connection cable 2
10
Be used for the connection
of special injector, T=0.8
17 103260037
Ultrasonic cleaner
assembly
1
Including: main unit,
bracket and cover
18 103250017 Reverse flush adaptor 6
19 101020131
Injector pulse signal
cables
1
20 199010019 Test liquid 1bottle 4L
21 199010035 Cleanser 2 bottles MIF-102, 355mL
22 104130024 O-ring 6 Φ23.6×2.65
23 104130026 O-ring 6 Φ27×2.45
24 104130030 O-ring 6 Φ7.1×2.65
25 104130022 O-ring 4 Φ32.5×2.65
26 104130023 O-ring 9 Φ20×2.65
27 104130024 O-ring 18 Φ23.6×2.65
28 104130028 O-ring 9 Φ6×1.8
29 104130029 O-ring 9 Φ4.87×1.8
30 104130032 O-ring 18 Φ15×2.65
31 104130033 O-ring 24 Φ23.6×1.8
Launch CNC 602 A  Troubleshooting:
1. The unit does not correspond when it is switched on. Check the fuse at lower right side of the unit and replace it (AC 250V/5A) if it is damaged or broken.
2. There is leakage in the fuel distributor coupler. Check the o-rings and replace it if it is damaged or unfitted. Do not tighten the two riffle screws too tightly; otherwise, it may cause leakage.
3. The fuel pressure drops slowly. The fuel pressure can not drop to zero within 1～2 minutes, slightly turn the overflow valve with inner hexagonal spanner counterclockwise.
4. The buzzer rings continually when there is no fuel pressure. The machine has fuel-lack warning function and it will ring when the liquid in the fuel tank is lack, and then automatically switch off the fuel pump and injectors and returns to the stop state. Supply the cleanser or test liquid to stop ringing. At this time, pressing [RUN] key is necessary to rerun the fuel pump and injectors.
5. Draining the test liquid in glass tube thoroughly requires pressing the [Drain] key more times. The solenoid valves will stop automatically after 15 seconds and it is necessary to drain more times if there is more liquid.
6. Malfunction code displaying E001. The malfunction code of E001 is displayed when the level inside fuel tank is lower than that of the required level. At this time, the buzzer will ring to remind user to supply fuel. If this situation appears during running process, the machine will stop the fuel pump ten seconds later and make “RUN” indicator is on the flashing state. After the liquid is up to the required specification(Press “Drain” key to drain the liquid into the fuel tank to resume the liquid level if there is lots of liquid, otherwise, supply the liquid.), the buzzer will stop ringing.
Precautions about using launch CNC 602 A:

•  read the operating instructions carefully before attempting to operate the unit. Keep this manual with the unit at all times.
• As the test liquid/cleanser used by CNC-602A is flammable, avoid fire during testing 
• Never switch on the ultrasonic system when there is no ultrasonic cleanser in the ultrasonic cleaning chamber. Otherwise, it may damage the ultrasonic cleaner. 
• Block the four wheels of CNC-602A before testing. 
• Avoid contact with hot surfaces such as exhaust pipes, coolant tank, etc. 
• Before testing, shift the transmission lever to NEUTRAL position, apply the parking brake and block the front wheels of the vehicle. 
• When disconnecting any connector of the pressurized fuel pipe on vehicle, wrap the connector with towel to prevent the fuel spurting out. Spurted fuel may cause personal injury or fire.

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