CHRYSLER A904(30RH), A999(32RH), CHRYSLER A500(42RH), A500SE(42RE)

VALVE BODY, FRONT PUMP, AND CASE CHANGES FOR 1995

CHANGE: Beginning at the start of production for all 1995 model A904(30RH), A999(32RH), A500(42RH), A500SE(42RE) rear drive transmissions, were built with a new design Front Pump, Valve Body, and a new design Main Case.

REASON: To increase pump flow and reduce front pump whine.

PARTS AFFECTED:
(1) FRONT PUMP ASSEMBLY - Has an additional inlet port in the pump cover for the 95/96 model year, as shown in Figure 1, to accommodate the changes in the main case. Find obd2 scanner? The pump body also recieved casting changes to enlarge the pump suction flow area.
(2) MAIN CASE - The rib in the case front pump face area, between the inlet ports was removed, as shown in Figure 2.
The inlet port on the valve body side was also enlarged which required casting changes, and is shown in Figure 4.
(3) VALVE BODY - Casting changes were necessary to enlarge the valve body inlet port in the transfer plate, as shown in Figure 3, to accommodate the case changes.
(4) SPACER PLATE - Inlet port made larger to accommodate the valve body transfer plate changes, as shown in Figure 3.
(5) PUMP GASKET - Added hole in the pump gasket to accommodate the changes to the pump assembly and the main case, as shown in Figure 5.

INTERCHANGEABILITY:
None of these components are interchangeable with previous model components! To ensure that the correct components have been installed, check the valve body to case interface after installation, to ensure that the seam of the valve body and case are identical.
Note: The pump gasket will retro-Jit back to all previous models, and the pump body and pump cover will retro-fit back, when used as a complete assembly, with the new gasket.

SERVICE INFORMATION:
Oil Pump Body Assembly (New Design)............................................................... 52118267
Reaction Shaft and Support Assembly, L/U (New Design).................................... 52118297
Reaction Shaft and Support Assembly, NLU (New Design) ...................................  3836511
Oil Pump Assembly Complete, Lock Up (New Design) .......................................... 4778552
Oil Pump Assembly Complete, Non Lock Up (New Design) ..................................  4778553
Oil Pump to Case Gasket (New Design) ................................................................. 52118266

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CHRYSLER A604 PLANETARY FAILURE

COMPLAINT: Before or after overhaul,premature planetary gear failure occurs.

CAUSE:
The cause may be:
1.  Damaged turbine shaft sealing rings or a scored surface where they ride in the rear of the pump cover.
2. A worn bushing in the rear of the turbine shaft where the underdrive clutch hub rides.
3. A restriction in the underdrive clutch hub lubrication holes.
4. Worn bushings in the overdrive clutch hub and shaft.
5. Worn or misplaced (moved) bushings in the 2-4 sun gear hub or a restriction in the two lube holes.
6. End clearance too loose allowing the input drum to "Walk" back and forth causing a loss of lube pressure because of a possible mis-alignment of the lubrication holes.
7. A restricted or blocked oil cooler restricting lubrication flow to the planetary gear train.
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CORRECTION:

Inspect and repair or replace as needed:
Inspect "Turbine Shaft" sealing rings and the sleeve area in the rear of the pump cover for wear. Apply compressed air into hole "A" in turbine shaft and ensure the air exit's through hole "B" freely.

Inspect the bushing in the rear of the turbine shaft for wear or scoring. Ensure that the bushing clearance to the Underdrive clutch hub shaft is no more than .003" to .006." Apply compressed air to hole "C," in the end of the Underdrive Clutch Hub Shaft, and ensure the air exits freely through holes "D" and "E" on the sides of the shaft as well as hole "F", which is the .062" hole in the "Splined" end of the shaft.

Inspect the bushings inside of the "Overdrive Clutch Hub Shaft" for wear or scoring and ensure a snug fit on the "Underdrive Clutch Hub Shaft." Inspect lube holes "G" and "H" and ensure that the bushings are not covering or restricting the lube holes. Replace the overdrive clutch hub and shaft as necessary.

Inspect the bushings in the "2-4 Sun Gear Hub" for wear or scoring and ensure a snug fit on the "Overdrive Clutch Hub Shaft." Inspect the bushing placement and ensure that the bushings have not "Walked" together causing the two .076" holes,"I" and "J", to be blocked or restricted. A small "Paper Clip" or "Scribe" bent at a 90° angle will serve as a good tool to check for restrictions in these lube holes.

After re-assembly of the transaxle is completed, "Turbine Shaft" end play "MUST' be measured with the use of a "Dial Indicator." This is "Critical, "Turbine Shaft End Play" must be between .005" to.015"

After the transaxle is installed into the vehicle check the amount of cooler flow entering the front cooler fitting by removing the cooler line and placing it into a container. Start the engine and ensure that more than 1 quart of fluid is flowing into the container every 20 seconds minimum. If there are any restrictions or not enough flow, the radiator or factory external cooler may require replacement. If the vehicle is equipped with the external "Cooler Bypass," ensure that the cooler lines are installed correctly onto the transaxle. If the transmission is equipped with the internal cooler bypass valve, the bypass valve is assembled correctly into the case.

SERVICE INFORMATION:
Overdrive Hub and Shaft (.050" larger in diameter)..........................................4659615
2-4 Sun gear and Hub (.050"larger bushing diameter).......................................4659618
NOTE: The overdrive clutch hub shaft was changed in diameter to prevent it from breaking. The 2-4 sun gear and hub was changed in diameter to acommodate the new overdrive clutch hub shaft. These parts will retro fit to previous design as long as they are used together. Some hot ones like Chrysler Adapter and Carman Vg Scanner also can help you more,if you need.

CHRYSLER A500/518 - PROPER DIRECT AND O.D. CLUTCH ASSEMBLY

1. Install direct clutch pressure plate on sliding hub with INSIDE LIP DOWN, as shown in Figure 1. Some obd2 scanner can help you more.

2. Install direct clutch plates beginning with a friction plate (See Figure 1) The number of direct clutch friction and steel plates depends on the engine size. See chart below.
　　FRICTION STEEL
A-500 3.9L ENGINE        5            4
A-500 5.2L ENGINE        6            5
A-518 ALL MODELS        8            7

3. Install direct clutch reaction plate in direct clutch housing with OUTSIDE LIP UP, as shown in Figure 1.

4 . Install direct clutch "Waved" snap ring which is the smallest diameter of the two waved snap rings.

NOTE: THE SLIDING HUB AND 800 POUND SPRING MUST BE COMPRESSED IN A BEARING PRESS TO INSTALL THIS SNAP RING. ALSO INSTALL THE SAFETY RETAINING RING ON THE SUN GEAR WHILE SPRING IS COMPRESSED.

5. Install the FLAT overdrive clutch snap ring into the groove in extension housing, as shown in Figure 1.

6. Install the WAVED overdrive clutch snap ring in the same groove on top of the flat snap ring, as shown in Figure 1.

7. Install overdrive clutch reaction plate (Thinnest) on top of the snap rings, as shown in Figure 1.

8. Install overdrive clutch plates beginning with a friction plate, and alternate with steel plate, as shown in Figure 1.and 2 steel plates on all models.

9. Install overdrive clutch pressure plate (Thickest) on top of the overdrive plates, as shown in Figure 1.

10. Install the ROUND wire retaining ring in groove in the extension housing, as shown in Figure 1, to retain the overdrive pack in position for assembly. Overdrive clutch requires 3 friction

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CHRYSLER A904 - SURGING BETWEEN 35-55 MPH

This bulletin supersedes Technical Service Bulletin 18-55-86, whick should be removed from your files. This repair only applies to subject vehicles equipped with a Federal Emission Package. It does not apply to 5.2L 2BBL heavy duty engines (identified by~a~ "4" in the eighth [engine] character of the VIN. Find more useful tools like ak400 and vas 5052?

SYMPTOM/CONDITION
Vehicle may exhibit a surge between steady speeds of 35 and 55 mph, with engine at full operating temperature.

DIAGNOSIS
Road test the vehicle at a steady speed between 35 and 55 mph to verify surge condition. Engine must be at full operating temperature. The surge normally is worse just after transmission lockup engagement.

PARTS REQUIRED
Drive Package PN 4419440 Consists of:
1 ESA/EFC Module                                            PN 4379255
1 6.2? Transmission Lock-Up Spring                                 PN 4202672
1 Transmission Pan Gasket                                        PN 4295875
1 Authorized Modification Label                                   PN 4275086

REPAIR PROCEDURE
This repair involves replacement of the transmission lock-up spring and a revised ESA/EFC module. The lock up speed will be raised from approximately 43 mph to 53 mph. And if you have cars, you can find some obd2 scanner to konw more about auto repair and car maintenance.

1. Raise vehicle on hoist, remove shift linkage and kickdown linkage, drain transmission fluid, and remove transmission pan.
2. Lower valve body just enough to remove torque converter lock-up spring, replace with supplied spring, PN 4202672. Re-use the existing lock-up valve, fail safe valve and spring, cover, and screws (Figure 1).
3. Reinstall valve body and torque screws to 100 inch pounds.
4. Reinstall transmission oil pan using supplied gasket, PN 4295875. Reconnect shift and kickdown linkage. Lower vehicle and refill using transmission fluid, PN 4318077. Adjust shift and kickdown linkages per the service manual procedures.
5. Remove ESA and replace with supplied ESA, PN 4379255.
6. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and attach near VECI label.

CHRYSLER 42RE 1-2 SHIFT SHUTTLE AFTER REBUILD

COMPLAINT: After rebuild, some vehicles may exhibit a 1-2 upshift shuttle condition that may lead you into thinking it is governor pressure or valve body related.

CAUSE: The cause may be, that you have adjusted the intermediate band incorrectly, or the seal rings on the 1-2 accumulator piston are leaking.

CORRECTION:
We have gotten into the habit of adjusting the intermediate band with a visual adjustment during the rebuild process, before we install the bottom pan. This is a grave mistake on the 42RE transmission. You must tighten the adjusting screw to 72 inch pounds, and then back the adjusting screw off exactly 3-5/8 turns, as shown in Figure 1. In some cases we have also
had to install the previous design 1-2 accumulator piston with steel seal rings as shown in Figure 2.


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MAZDA/FORD GF4A-EL/GF4EAT HARSH UPSHIFTS

COMPLAINT: 1993 & up, vehicles equipped with GF4A-EL transaxles, built before 1/3/95, may exhibit a harsh 1-2 upshift or harsh upshift complaints before or after overhaul. Line pressure appears to be normal or slightly higher than normal when checking in the "D" range. "Normal" line pressure readings are as follows, 60-78psi. at idle and 161-172 psi. at stall.

CAUSE: The cause may be, higher than normal control pressure passing through the main control spacer plate.

CORRECTION: Replace the Pressure Control Solenoid as shown in Figure 1 with Ford part number F32Z-7G136-AA or Mazda part number FU9A-21-1G1A. Inspect the Pressure Regulator Valve and the Pressure Regulator Valve bore for  wear or scoring. Inspect the Boost Valve and Boost Valve Sleeve for wear or scoring. Ensure that there is no "side to side" wobble of the Pressure Regulator Valve, when it is in its bore.See Figure 2. Enlarge the Pressure Regulator "balance" orifice in the rear control spacer plate to .056" as shown in Figure 3.

SERVICE INFORMATION:
PRESSURE CONTROL SOLENOID (FORD)........................................F32Z-7G136-AA
PRESSURE CONTROL SOLENOID (MAZDA).....................................FU9A-21-1G1A
NOTE: THESE TWO PART NUMBERS ARE FOR THE SAME SOLENOID.
 


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THM 3T40 (125C) - Pump Rotor And Slide Changes

CHANGE: Beginning in late 1985, the dimensions of the pump rotor and pump slide changed (See Figure 1).

REASON: Improved pump capacity.

PARTS AFFECTED
(1) PUMP ROTOR - The outside diameter of the rotor was made smaller. The previous rotor O.D. was 2.235", and the present rotor O.D. is 2.210". (See Figure 1).
(2) PUMP SLIDE - The height of the pump slide stop was made shorter. The previous pump slide stop measures .426", and the present pump slide stop measures .406" (See Figure 1).

INTERCHANGEABILITY:
The pump rotor and pump slide are interchangeable. "ONLY AS A SET". You CANNOT mix these parts.
(1) If you install the previous (Large) rotor with the present (Short) slide, interference will result and usually strip the rotor splines.
(2) If you install the present (Small) rotor with the previous (Tall) slide, erratic line pressures can be encountered.
(3) DO NOT MIX THESE PARTS.
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SERVICE INFORMATION: