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Skoda - Auto - skoda-karoq-2017-110444
Skoda - Auto - skoda-karoq-2017-brukerhandbok-110449
Cars & Automotive Accessories - Kenwood - C929
Skoda - Auto - skoda-karoq-2017-savininko-vadovas-110446
Toys & Accessories - Lego - DUPLO Town - AROUND THE WORLD - 10805
Skoda - Auto - skoda-karoq-2017-navod-k-obsluze-110433
Skoda - Auto - skoda-karoq-2017-manual-del-propietario-110438
Skoda - Auto - skoda-karoq-2017-omistajan-kasikirja-110439
Skoda - Auto - skoda-karoq-2017-110460
VCRs & Accessories - Hitachi Electronics - VTM171A
Skoda - Auto - skoda-karoq-2017-110457
Skoda - Auto - skoda-karoq-2017-110431
Skoda - Auto - skoda-karoq-2017-kullan-m-k-lavuzu-110458
1981-1995--Chrysler--Lebaron--4 Cylinders C 2.2L FI Turbo SOHC--31006701
Skoda - Auto - skoda-karoq-2017-omaniku-kasiraamat-110436
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31034803
Skoda - Auto - skoda-karoq-2017-instrukcja-obslugi-110450
Skoda - Auto - skoda-karoq-2017-prirocnik-za-lastnika-110456
Skoda - Auto - skoda-karoq-2017-110453
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts_5d8a7f921c3648a62136367
Skoda - Auto - skoda-karoq-2017-uzivatelska-prirucka-110455
1981-1995--Chrysler--Lebaron--4 Cylinders J 2.5L MFI Turbo SOHC--31006702
Skoda - Auto - skoda-karoq-2017-ipasnieka-rokasgramata-110447
Barossa - Motorcycle - Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-110441
Pool Equipment - Haywood-Pool - Super Pump~All Super Pump Models
Sewing Machine - Singer - 14T968DC %7C PROFESSIONAL 5
1981-1995--Chrysler--Lebaron--4 Cylinders B 2.2L 2BL SOHC--31218101
Skoda - Auto - skoda-karoq-2017-manuel-du-proprietaire-110440
Skoda - Auto - skoda-karoq-2017-manuale-del-proprietario-110445
Skoda - Auto - skoda-karoq-2017-110432
Skoda - Auto - skoda-karoq-2017-110459
Skoda - Auto - skoda-karoq-2017-agarmanual-110454
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31095601
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.6L 2BL SOHC--31218102
Furniture & Storage - Blue Rhino - GAD1375SP
Skoda - Auto - skoda-karoq-2017-handleiding-110448
Speakers & Audio Accessories - Dual - Dual - SX652 ~ SX692
Skoda - Auto - skoda-karoq-2017-manualul-de-utilizare-110452
Skoda - Auto - skoda-karoq-2017-vodic-za-korisnike-110442
Skoda - Auto - skoda-karoq-2017-kezelesi-utmutato-110443
Barossa - Motorcycle - Barossa__Barossa_PYTHON_100cc_parts
Skoda - Auto - skoda-karoq-2017-instruktionsbog-110435
1981-1995--Chrysler--Lebaron--4 Cylinders D 2.2L TBI SOHC--31034802
Skoda - Auto - skoda-karoq-2017-owner-s-manual-110437
Printers & Accessories - Xerox - WorkCentre Pro C2128~C2636~C3545
Cars & Automotive Accessories - Kenwood - DPX-510
Video Cameras, Camcorders, & Accessories - Canon - ZR900 Camcorder
Grills & Accessories - Blue Rhino - Blue Rhino WAD996SP
Sewing Machine - Brother - Brother BAS-511
Ducati - Motorcycle - Ducati_M620_ie_Parts_2002
Cameras & Accessories - Nikon - Nikon COOLPIX S203
Speaker Systems - JBL - Xtreme
Skoda - Auto - skoda-karoq-2017-manual-do-proprietario-110451
Printers & Accessories - Epson - Stylus Pro 9000
Sewing Machine - Brother - Brother DB2-B798
Cars & Automotive Accessories - Ford - F-150 2001
Power Tools & Accessories - STIHL - STIHL Trimmer FS 40, FS 50
DJ Equipment - Kramer AV - VM-4HDT
Printers & Accessories - Epson - WorkForce 40
Summary of Content
FORD 4R100 "UPDATE HANDBOOK" INDEX 3 PRELIMINARY DIAGNOSTIC INFORMATION .................................................................................... 6 IDENTIFICATION TAG LOCATION AND INFORMATION ................................................................ 9 LUBE ORIFICE PLUG AND EXTENSION HOUSING INFORMATION ............................................. 11 MANUAL LEVER IDENTIFICATION ....................................................................................................... 12 COOLER BYPASS VALVE DIFFERENCES .............................................................................................. 14 PUMP COVER VALVES EXPLODED VIEW ............................................................................................ 15 PUMP STATOR DIFFERENCES ................................................................................................................. 16 COAST CLUTCH HOUSING DIFFERENCES .......................................................................................... 18 OVERDRIVE ROLLER CLUTCH DIFFERENCES ................................................................................. 19 OVERDRIVE FRICTION DIFFERENCES ................................................................................................ 20 VALVE BODY CHECKBALL LOCATIONS .............................................................................................. 21 LOWER VALVE BODY SPACER PLATE IDENTIFICATION ............................................................... 22 MAIN CASE CHECKBALL LOCATIONS ................................................................................................ 23 ALL VALVE BODIES EXPLODED VIEWS .............................................................................................. 25 ELECTRONIC COMPONENT RESISTANCE CHARTS ........................................................................ 27 SOLENOID CONNECTOR PIN IDENTIFICATION ................................................................................ 29 TROUBLE CODE CHART AND DESCRIPTION ..................................................................................... 34 POWER TAKE OFF DESCRIPTION AND OPERATION ....................................................................... 38 "NON-PTO" AND "PTO" HYDRAULIC DIFFERENCES ...................................................................... 39 MAIN CASE CENTRAL LUBE ADDED .................................................................................................... 40 SPACER PLATE DIFFERENCES PTO AND NON-PTO ......................................................................... 50 "NON-PTO" AND "PTO" PUMP DIFFERENCES ................................................................................... 56 PWM SOLENOID PACK RESISTANCE CHART ..................................................................................... 57 SIX PINION FORWARD AND REAR PLANETARY CARRIERS .......................................................... 60 NEW DESIGN SUN SHELL ......................................................................................................................... 64 INTERMEDIATE DIODE FREEWHEEL FAILURE ............................................................................... 67 HYDRAULIC PASSAGE IDENTIFICATION ............................................................................................ 77 NO TCC AT LESS THAN 30% THROTTLE ............................................................................................. NEW "SPECIAL" 4R100 CASE FOR E4OD REPLACEMENT ............................................................. 82 97 ARTICLE ON PTO OPERATION.................................................................................................................. PTO OIL CIRCUIT DIAGRAMS..................................................................................................................... 100 AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107 AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 Copyright © ATSG 2005 INTRODUCTION Original Printing February, 2005 FORD 4R100 "UPDATE HANDBOOK" Since the introduction of the 4R100 transmission in model year 1998, there have been many engineering changes to improve Pleaseability, Reliability and Durability concerns. These changes have affected most every part used in this transmission. This "Update Handbook" will explain each change, the reason for the change, and any parts interchangeability concerns created by the change, along with any part numbers needed to update your transmission. We wish to thank Ford Motor Company for the information and some illustrations that have made this booklet possible. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 2005 DALE ENGLAND JIM DIAL FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT WAYNE COLONNA ED KRUSE TECHNICAL SUPERVISOR TECHNICAL CONSULTANT PETER LUBAN GREGORY LIPNICK TECHNICAL CONSULTANT TECHNICAL CONSULTANT JON GLATSTEIN DAVID CHALKER TECHNICAL CONSULTANT TECHNICAL CONSULTANT JERRY GOTT ROLAND ALVAREZ TECHNICAL CONSULTANT TECHNICAL CONSULTANT GERALD CAMPBELL MIKE SOUZA TECHNICAL CONSULTANT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 1 Technical Service Information FORD 4R100 PRELIMINARY INFORMATION CHANGE: Beginning at the start of production for 1999 models, Ford Motor Company introduced a new transmission in some F250, F350, F450 and F550 Super Duty Trucks, equipped with the 5.4L, 6.8L and 7.3L engines. Basically the new 4R100 is a revised version of the previous E4OD transmission with a Power-Take-Off (PTO) window on the side of the case (See Figure 1). The revisions that have occured however, have created many major engineering changes that have affected many internal and external parts that will affect service. REASON: Provided a PTO option for Ford Motor Company. PARTS AFFECTED: (1) TRANSMISSION CASE - Now has a PTO window added to the left side of the case directly behind the front pump area, and a Turbine Speed Sensor has been added at the top of the case and triggered by a revised coast clutch drum (See Figure 2). Another change to the rear of the case is the addition of a Lube Orifice Plug to the Rear of the case, as shown in Figure 4, which also changes the extension housings. (2) TURBINE SPEED SENSOR - Added to the top front of the case on some models, as shown in Figure 2. We have also provided you with the resistance readings and OEM part numbers on both Turbine Speed Sensors, as the PTO and Non-PTO models use different sensors. Refer to Figure 2 for turbine speed sensor information. (3) OUTPUT SHAFT SENSOR - Output Shaft Speed sensor was added to the top of the extension housing on some models, as shown in Figure 2. OSS is triggered by an added rotor pressed onto the output shaft, which requires a new tool to position the speed rotor properly if it is removed during overhaul, as shown in Figure 3. The park gear is also now pressed onto the output shaft, and the number 13 thrust washer has been changed to a thrust bearing as shown in Figure 3. We have provided you with the resistance reading and the OEM part numberfor the output shaft speed sensor. Refer to Figure 2 for output shaft speed sensor information. (4) LUBE ORIFICE PLUG - Added to the rear of the case in the lube circuit to provide added lubrication to the extension housing bushing on 2WD models. To retain common cases the 4WD models will also have the lube orifice plug installed, as well as E4OD cases produced after July 24, 1997. Lube Orifice Plug is available under OEM part number F81Z-7E380-AA, and should be replaced on rebuild. Refer to Figure 4. (5) EXTENSION HOUSING - Has an added boss or shoulder to retain the lube orifice plug in position in the transmission case, as shown in Figure 5. Notice that the 6.8L and 7.3L, 2 wheel drive extension housing has added a new passage to the extension housing bushing, much like the 4L80E. All 4R100 and E4OD transmissions equipped with the lube orifice plug must use an extension housing with the shoulder or boss. Failure to do so could blow the lube orifice plug out and exhaust all lube oil, which would be catastrophic. Refer to Figure 5. Continued on next Page. AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2005 ATSG 3 Technical Service Information PARTS AFFECTED: (Continued) (6) MANUAL SHIFT LEVER - There are two different external shift levers for this unit, one for NonPTO transmissions and one for transmissions with the PTO option, as shown in Figure 6. We have provided you with the "Stamping" number as well as the OEM part number for both, as shown in Figure 6. (7) COOLER BYPASS VALVE - Similar to the Cooler Bypass Valve on the E4OD that provides lubrication to the transmission in case of blocked or partially blocked coolers. We have given you OEM part numbers for both and both bypass valves are illustrated in Figure 7. (8) TRANSMISSION COOLERS - Most F-Series vehicles over 8500 GVW equipped with the 4R100 transmission have an external "Oil-To-Air" cooler only. Due to the internal design of the "Oil-ToAir" cooler, it cannot be adequately flushed to remove contaminants, and requires replacement during transmission rebuild. The only exception is that F-Series vehicles over 8500 GVW equipped with the 5.4L engine also uses a radiator "In-Tank" cooler in addition to the "Oil-To-Air" cooler. Refer to Figure 8 for transmission cooler information. (9) FRONT PUMP COVER - The pump cover is basically the same as the E4OD, but has a different valve line-up in the Converter Clutch Control Valve bore. The gasoline applications all have an "On-Off" lock-up solenoid and the 7.3L diesel applications all have a Pulse Width Modulated (PWM) lock-up solenoid. This changes the Converter Clutch Control Valve line-ups in the pump cover, as shown in Figure 9. (10) FRONT PUMP STATOR SHAFT - With the addition of the PTO gear on the front of the coast clutch drum, it was necessary to move the coast clutch sealing ring grooves up on the pump stator shaft to accommodate the coast clutch drum moving. There are currently three different Pump Stator Shafts used in production and all three are illustrated in Figure 10. One is the current E4OD shaft which is used with the "Cast Iron" coast clutch drum with 5.4L and 6.8L engines without the PTO option. Two is the shaft with the relocated sealing rings and a bushing in the pump tower, which is used with the "Stamped Steel" coast clutch drum with 5.4L and 6.8L engines without the PTO option. Third is the shaft with the relocated sealing rings and a caged needle bearing in the pump tower, which is used with the "Stamped Steel" coast clutch drum with 6.8L and 7.3L engines with the PTO option. Refer to Figure 10. (11) COAST CLUTCH DRUM AND STEEL PLATES - There is now a revised "Stamped Steel" coast clutch drum introduced with the 4R100 transmission. There are currently three different coast clutch drums used in production and all three are illustrated in Figure 11. One is the current E4OD coast clutch drum which is "Cast Iron" and uses the current steel plates. Two is the new design "Stamped Steel" coast clutch drum without the PTO gear pressed on it and uses a new design coast clutch steel plate to accommodate the new drum. Third is the new design "Stamped Steel" coast clutch drum with the PTO gear pressed on it and uses the new design coast clutch steel plates to accommodate the new drum. The new design "Stamped Steel" coast clutch drum now has the overdrive roller clutch inner cam made on the drum and the overdrive sun gear is pressed into the new design drum, which changes the assembly process of the overdrive roller clutch. Refer to Figure 11. (12) COAST CLUTCH PISTON - The coast clutch piston in the new design coast clutch drum is now a stamped steel, molded rubber seals assembly and is illustrated in Figure 12. The new design piston assembly requires a new seal protector tool, Rotunda No. 307-387, to install the piston and seal assembly into the new design stamped steel coast clutch drum (See Figure 12). Continued on next Page. 4 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2005 ATSG Technical Service Information PARTS AFFECTED: (Continued) (13) OVERDRIVE ROLLER CLUTCH - The overdrive roller clutch inner cam is now made onto the new design coast clutch drum, instead of being splined like the previous models were, and is illustrated in Figure 13. The new design overdrive roller clutch assembly is now assembled onto the inner cam on the new design drum. The overdrive roller clutch outer race is still located in the overdrive ring gear next to the overdrive carrier and the number 13 thrust washer between the two is now plastic, but the cage and roller assembly are now assembled over the inner race on the new design coast clutch drum. Refer to Figure 13. (14) OVERDRIVE FRICTION PLATES - Now have wider teeth to accommodate the new design stamped steel coast clutch drum assembly when it is used, as illustrated in Figure 14. (15) VALVE BODY CHECKBALL LOCATIONS - Valve body checkball locations are illustrated in Figure 15 and now has two 1/4" checkballs and two 5/16" checkballs. This of course changes the lower valve body spacer plate as illustrated in Figure 16. The new design spacer plate has only one hole over the bathtub where the checkball was removed. The case checkball locations remain the same as the 1996-Up configuration, and this illustration is included for reference and shown in Figure 17. (16) VALVE LINE-UPS IN VALVE BODY - Have changed from the previous models and are illustrated in Figure 18, with a valve description and legend shown in Figure 19. (17) SOLENOID BODY - There are now two different Solenoid Bodies, depending on whether you have a gasoline or diesel model. Since the diesel models now have a Pulse Width Modulated (PWM) converter clutch application, the resistance on the converter clutch solenoid in the Solenoid Body is going to be different. We have included the OEM part numbers for both solenoid bodies and resistance charts for all solenoids in Figure 20, and you will find solenoid application and pin function charts in Figures 21 and 22. (18) TROUBLE CODES - Abbreviations are listed in Figure 23 and OBD II Trouble Codes are listed in numerical order in Figures 24 through 28. INTERCHANGEABILITY: All of the parts listed above are model sensitive, and some of the parts listed above cannot be intermixed with E4OD parts. With this unit you will have to be very carefull if replacement of the various components becomes necessary. SERVICE INFORMATION: Turbine Shaft Speed Sensor (PTO Models Only) ............................................ Turbine Shaft Speed Sensor (Non-PTO Models Only) .................................... Output Shaft Speed Sensor (All Models) ......................................................... Lube Orifice Plug (Plastic) ............................................................................... External Manual Shift Lever (With PTO Option) ............................................ External Manual Shift Lever (Without PTO Option) ....................................... Cooler Bypass Valve Assembly ....................................................................... Coast Clutch Piston (New Design) ................................................................... Solenoid Body Assembly (Gasoline Engine Only) .......................................... Solenoid Body Assembly (Diesel Engine Only) .............................................. Overdrive Roller Clutch And Cage Assembly ................................................. F81Z-7M101-BA F81Z-7M101-AA F81Z-7M101-AA F81Z-7E380-AA F81Z-7A256-AA F7UZ-7A256-BB F81Z-7H322-AA F81Z-7A262-AA F81Z-7G391-BA F81Z-7G391-AB F81Z-7A089-AB Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 5 Technical Service Information FORD 4R100 WITH POWER TAKE OFF OPTION Note: PTO is available as an option on 8500 GVW or above, Super Duty F-Series trucks with 6.8L gasoline and 7.3L Diesel engines. Ford 4R100 transmissions on other models are not PTO capable. Ford XW4P-AC RJL-B 004361 17 BD-9C BA -7006- RFF81P 98 d For Year BD- 6520 1 2 3 4 004361 1 2 3 4 9 9=1999 0=2000 1=2001 2=2002 3=2003 4X4 5G XW4P-AC RJL-B 004361 BD-9C17 Build Date Month Day C 17 A=Jan B=Feb C=Mar D=Apr E=May F=Jun G=Jul H=Aug J=Sep K=Oct L=Nov M=Dec Assembly Part Number, Prefix And Suffix Transmission Model Serial Number Build Date (Year, Month, Day) Copyright © 2005 ATSG Figure 1 6 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Turbine Shaft Speed Sensor Output Shaft Speed Sensor PTO Models Only = 496-1244 Ohms Resistance Part Number F81Z-7M101-BA All Models = 781-1979 Ohms Resistance Part Number F81Z-7M101-AA Non PTO Models Only = 781-1979 Ohms Resistance Part Number F81Z-7M101-AA Ford 6520 F8T1-DB PRA-YC 00001447 BD-8J03 00001447 4X4 50 CL RAL Ford F7TP-7F293-AA NEUT Copyright © 2005 ATSG Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP 7 Technical Service Information FORD 4R100 OUTPUT SHAFT SPEED SENSOR ROTOR Output Shaft Speed Sensor Rotor is press fit to the output shaft and requires new Spacer Tool, Rotunda No. 307-388 for spacing the speed sensor rotor the proper distance from the park gear, if it was removed from the output shaft during service. PARK GEAR The Park Gear is also press fit to the output shaft, and the number 13 thrust washer, between the case and the park gear has been replaced with a needle bearing. SPACER, ROTUNDA PART NUMBER 307-388 OUTPUT SHAFT SPEED SENSOR ROTOR PARK GEAR OUTPUT SHAFT Figure 3 8 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2005 ATSG Technical Service Information FORD 4R100 LUBE ORIFICE LOCATION LUBE ORIFICE PLUG FORD PART NUMBER F81Z-7E380-AA Copyright © 2005 ATSG Figure 4 AUTOMATIC TRANSMISSION SERVICE GROUP 9 Technical Service Information EXTENSION HOUSINGS 4R100 TYPICAL 4 WHEEL DRIVE E4OD 4X4 WITHOUT LUBE PLUG SHOULDER FORD 4R100 6.8L AND 7.3L 2 WHEEL DRIVE NO SHOULDER ALL OTHER 2 WHEEL DRIVE APPLICATIONS ADDED BOSS E4OD WITHOUT LUBE PLUG SHOULDER NO SHOULDER NOTE: Extension Housings are model sensitive. Refer to Ford Motor Co. parts list for proper part numbers. Copyright © 2005 ATSG Figure 5 10 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 MANUAL SHIFT LEVERS "With" PTO OPTION "Without" PTO OPTION STAMPED F81P-AA STAMPED F75P-BB FORD PART NUMBER F81Z-7A256-AA FORD PART NUMBER F7UZ-7A256-BB Copyright © 2005 ATSG Figure 6 AUTOMATIC TRANSMISSION SERVICE GROUP 11 Technical Service Information TO COOLER SEALING WASHERS "E4OD" COOLER BYPASS VALVE ASSEMBLY FROM COOLER SEALING WASHERS OEM PART NUMBER F75Z-7H322-AB COOLER LINE FITTINGS "4R100" COOLER BYPASS VALVE ASSEMBLY TO COOLER SEALING WASHERS FROM COOLER SEALING WASHERS COOLER LINE FITTINGS OEM PART NUMBER F81Z-7H322-AA Copyright © 2005 ATSG Figure 7 12 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Most F-Series vehicles over 8500 GVW equipped with the 4R100 transmission have an external "Oil-ToAir" cooler only. Due to the internal design the "Oil-To-Air" cooler cannot be adequately flushed to remove contaminants, and requires replacement during transmission rebuild. "OIL TO AIR" COOLER The only exception is that F-Series vehicles over 8500 GVW equipped with the 5.4L engine also uses a radiator "In-Tank" cooler in addition to the "Oil-To-Air" cooler. "OIL TO AIR" COOLER COOLER LINES FROM TRANSMISSION TO COOLER IN RADIATOR Copyright © 2005 ATSG Figure 8 AUTOMATIC TRANSMISSION SERVICE GROUP 13 Technical Service Information FORD 4R100 VALVE LINE-UPS IN PUMP ASSEMBLY 15 Diesel Engine PWM Only. 12 23 14 11 8 9 Gasoline Engine "On-Off" Only. 10 11 1 2 3 4 1. Pressure Regulator Valve 2. Spring Retainer 3. Pressure Regulator Outer Spring 4. Pressure Regulator Inner Spring 5. Pressure Regulator Boost Valve 6. Pressure Regulator Boost Valve Sleeve 7. Snap Ring 8. Converter Clutch Regulator Valve 9. Converter Clutch Regulator Spring 10. Converter Clutch Regulator Bore Plug 11. Bore Plug Retainer 12. Converter Clutch Control Valve (Gas "On-Off" Only) 13. Converter Clutch Control Spring (Gas "On-Off Only) 14. Converter Clutch Control Bore Plug 15. Converter Clutch Control Line-up (Diesel "PWM" Only) 5 6 7 Copyright © 2005 ATSG Figure 9 14 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information BUSHING COAST CLUTCH SEAL RINGS ARE LOW ON PUMP TOWER (LIKE E4OD) USED WITH THE "CAST IRON" COAST CLUTCH DRUM WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION BUSHING COAST CLUTCH SEAL RINGS ARE HIGHER ON THE PUMP TOWER USED WITH THE "STAMPED STEEL" COAST CLUTCH DRUM WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION CAGED NEEDLE BEARING COAST CLUTCH SEAL RINGS ARE HIGHER ON THE PUMP TOWER The Caged Needle Bearing shown here, allegedly never made it to production, but we have seen some out there. USED WITH THE "STAMPED STEEL" COAST CLUTCH DRUM WITH 6.8L AND 7.3L "WITH" PTO OPTION Copyright © 2005 ATSG Figure 10 AUTOMATIC TRANSMISSION SERVICE GROUP 15 Technical Service Information COAST CLUTCH STEEL PLATES "CAST IRON" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION COAST CLUTCH STEEL PLATES "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION COAST CLUTCH STEEL PLATES "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 6.8L AND 7.3L "WITH" PTO OPTION Copyright © 2005 ATSG Figure 11 16 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information STAMPED STEEL MOLDED RUBBER COAST CLUTCH PISTON FOR NEW DESIGN COAST CLUTCH DRUM NEW DESIGN STAMPED STEEL, MOLDED RUBBER SEAL PISTON OEM PART NUMBER F81Z-7A262-AA NEW DESIGN STAMPED STEEL COAST CLUTCH DRUM LIP SEAL PROTECTOR ROTUNDA NO. 307-387 NEW DESIGN STAMPED STEEL MOLDED RUBBER PISTON Copyright © 2005 ATSG Figure 12 AUTOMATIC TRANSMISSION SERVICE GROUP 17 Technical Service Information Snap Ring Number 3 Thrust Washer is now Plastic. Overdrive Ring Gear Overdrive Roller Clutch Outer Race OVERDRIVE ROLLER CLUTCH AND CAGE ASSEMBLY PART NUMBER F81Z-7A089-AA The rollers and plastic cage are smaller and no longer assembled into the back of the overdrive ring gear. The outer race remains in the back of the overdrive ring gear next to the overdrive carrier, but the rollers and cage are now installed over the inner race on the new design coast clutch drum. New Design "Stamped Steel" Coast Clutch Drum Assembly Copyright © 2005 ATSG Figure 13 18 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information OVERDRIVE CLUTCH FRICTION PLATES "CAST IRON" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION OVERDRIVE CLUTCH FRICTION PLATES "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 5.4L AND 6.8L "WITHOUT" PTO OPTION OVERDRIVE CLUTCH FRICTION PLATES "STAMPED STEEL" COAST CLUTCH DRUM USED WITH 6.8L AND 7.3L "WITH" PTO OPTION Copyright © 2005 ATSG Figure 14 AUTOMATIC TRANSMISSION SERVICE GROUP 19 Technical Service Information FORD 4R100 4R100 VALVE BODY CHECKBALL LOCATIONS REQUIRES TWO 1/4" RUBBER BALLS, AND TWO 5/16" RUBBER BALLS ROUGH FORGING NUMBER LOCATION RF-F6TP7A092-AB X 5/16" DIAMETER CHECKBALL 5/16" DIAMETER CHECKBALL 1/4" DIAMETER CHECKBALLS Copyright © 2005 ATSG Figure 15 20 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "Two" Holes Over The Bathtub 1996-1999 "E4OD" LOWER VALVE BODY SPACER PLATE IDENTIFICATION ONE "V" NOTCH THREE "SMALL" HOLES "One" Hole Over The Bathtub 1999 MODEL "4R100" LOWER VALVE BODY SPACER PLATE IDENTIFICATION ONE "DOVETAIL" NOTCH THREE "SMALL" HOLES Copyright © 2005 ATSG Figure 16 AUTOMATIC TRANSMISSION SERVICE GROUP 21 Technical Service Information 1999 4R100 CASE CHECKBALL LOCATIONS REQUIRES EIGHT (5/16") RUBBER BALLS CB-8 CB-7 BS-3 BS-1 CB-6 CB-1 INTERMEDIATE ACCUMULATOR REGULATOR CB-14 FILTER ASSEMBLY SHIFT 1 AIR BLEED CB-9 SHIFT 2 AIR BLEED 1/4" STEEL BALL EPC RELIEF BALL Filter Assembly ......... F1TZ-7H194-A EPC Spring ............... E9TZ-7D017-A SPRING GOES INTO THE CASE FIRST SPRING GOES INTO THE CASE FIRST (USED ALL MODELS) Copyright © 2005 ATSG Figure 17 22 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 MAIN, LOWER, AND ACCUMULATOR VALVE BODIES EXPLODED VIEW 1 2 5 4 8 7 6 9 3 14 15 13 11 10 12 12 20 30 29 28 19 18 17 16 TP- B RF-F6 92-A 7A0 32 31 33 37 36 34 38 24 39 35 23 22 26 44 21 25 27 43 40 42 41 46 73 72 71 70 47 69 48 68 67 49 66 65 50 64 51 52 54 63 53 62 55 61 56 57 58 59 Copyright © 2005 ATSG 60 Figure 18 AUTOMATIC TRANSMISSION SERVICE GROUP 23 Technical Service Information FORD 4R100 MAIN, LOWER, AND ACCUMULATOR VALVE BODY LEGEND Item Description Item Description 1 Lower Valve Body 47 Spring Clip Bore Plug Retainer 2 Hex Head Bolt, M1 X 36 (2 Required) 48 Direct Clutch Accumulator Regulator Plunger Bore Plug 3 Retaining Plate 49 Direct Clutch Accumulator Regulator Plunger Spring 4 Manual 1-2 Transition Valve Spring 50 Direct Clutch Accumulator Regulator Plunger 5 Manual 1-2 Transition Valve 51 Direct Clutch Accumulator Regulator Valve Retainer 6 Spring Clip Bore Plug Retainer 52 Direct Clutch Accumulator Regulator Valve Spring 7 Engagement Valve Bore Plug 53 Direct Clutch Accumulator Regulator Valve 8 Engagement Valve Spring 54 Spring Clip Bore Plug Retainer 9 Engagement Valve 55 O.D. Clutch Accumulator Regulator Plunger Bore Plug 10 Main Valve Body 56 O.D. Clutch Accumulator Regulator Plunger Spring 11 Checkball 1/4", 2 Required (7E195) 57 O.D. Clutch Accumulator Regulator Plunger 12 Checkball 5/16", 2 Required (7E195) 58 O.D. Clutch Accumulator Regulator Valve Retainer 13 Manual Control Valve 59 O.D. Clutch Accumulator Regulator Valve Spring 14 Manual Valve "E" Clip 60 O.D. Clutch Accumulator Regulator Valve 15 Spring Clip Bore Plug Retainer 61 Spring Clip Bore Plug Retainer 16 Low Reverse Modulator Valve Sleeve 62 Int. Clutch Accumulator Regulator Plunger Bore Plug 17 Low Reverse Modulator Valve Plunger 63 Int. Clutch Accumulator Regulator Plunger Spring 18 Low Servo Modulator Valve Spring 64 Int. Clutch Accumulator Regulator Plunger 19 Low Servo Modulator Valve 65 Int. Clutch Accumulator Regulator Valve Retainer 20 Low Reverse Modulator Valve 66 Int. Clutch Accumulator Regulator Valve Spring 21 Spring Clip Bore Plug Retainer 67 Int. Clutch Accumulator Regulator Valve 22 3-4 Shift Valve Bore Plug 68 Spring Clip Bore Plug Retainer 23 3-4 Shift Valve Spring 69 Line Pressure Modulator Plunger Sleeve 24 3-4 Shift Valve 70 Line Pressure Modulator Plunger 25 Retaining Plate 71 Line Pressure Modulator Spring And Retainer Assembly 26 2-3 Shift Valve Spring 72 Line Pressure Modulator Valve Spring 27 2-3 Shift Valve 73 Line Pressure Modulator Valve 28 Retaining Plate 29 Solenoid Regulator Valve Spring 30 Solenoid Regulator Valve 31 Retaining Plate 32 Coast Clutch Shift Valve Spring 33 Coast Clutch Shift Valve 34 Retaining Plate 35 4-3-2 Shift Timing Control Valve Plunger Spring 36 4-3-2 Shift Timing Control Valve Plunger 37 Retaining Plate 38 4-3-2 Shift Timing Valve 39 4-3-2 Shift Timing Valve Spring 40 Spring Clip Bore Plug Retainer 41 1-2 Shift Valve Bore Plug 42 1-2 Shift Valve 43 Drive 2 Valve 44 1-2 Shift Valve Spring 46 Accumulator Valve Body (7G422 Model Sensitive) Copyright © 2005 ATSG Figure 19 24 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 SOLENOID RESISTANCE CHARTS Solenoid Resistance Chart Solenoid Body Solenoid Pin Numbers Shift Solenoid "B" (2) Shift Solenoid "A" (1) TCC Solenoid, Gasoline (On-Off) TCC Solenoid, Diesel (PWM) Coast Clutch Solenoid Electronic Pressure Control Solenoid Transmission Fluid Temp Sensor 1 and 2 1 and 3 1 and 4 1 and 4 1 and 5 11 and 12 7 and 8 Resistance 20-30 Ohms 20-30 Ohms 20-30 Ohms 10-20 Ohms 20-30 Ohms 3.0-5.0 Ohms See Chart Below Transmission Fluid Temperature °C °F Resistance -40 to -20 -19 to -1 0 - 20 21-40 41-70 71-90 91-110 111-130 131-150 -40 to -4 -3 to 31 32-68 69-104 105-158 159-194 195-230 231-266 267-302 1062k - 284k W 284k - 100k W 100k - 37k W 37k - 16k W 16k - 5k W 5k - 2.7k W 2.7k - 1.5k W 1.5k - 0.8k W 0.8k - 0.54k W SOLENOID ASSEMBLY Gasoline Engines Only - Part Number = F81Z-7G391-BA Diesel Engines Only ----- Part Number = F81Z-7G391-AB Copyright © 2005 ATSG Figure 20 AUTOMATIC TRANSMISSION SERVICE GROUP 25 Technical Service Information Shift Solenoid Application Chart Selector Lever Commanded Range Gear P/R/N D D D D D Cancel MANUAL 2 MANUAL 1 MANUAL 1 * 1 1 2 3 4 Shift Solenoid "A" Shift Solenoid "B" TCC Solenoid Coast Clutch Solenoid ON ON ON OFF OFF OFF OFF ON ON OFF * * * * * * * * * * First Through 3rd Gear Only, SSA, SSB, TCC, Same as Overdrive, CCS Always On. 2 2 1 * * * OFF ON OFF OFF OFF OFF ON ON ON Controlled by PCM SHIFT SOLENOID "A" ALWAYS OFF Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 4 2 1 2nd 3 2 2 3rd 3 2 2 4th 4 2 2 SHIFT SOLENOID "B" ALWAYS OFF Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 1 2 1 2nd 1 2 1 3rd 4 2 2 4th 4 2 2 SHIFT SOLENOID "A" ALWAYS ON Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 1 2 1 2nd 2 2 1 3rd 2 2 1 4th 1 2 1 SHIFT SOLENOID "B" ALWAYS ON Selector Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1st 2 2 1 2nd 2 2 1 3rd 3 2 2 4th 3 2 2 Copyright © 2005 ATSG Figure 21 26 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 SOLENOID BODY PIN IDENTIFICATION AND FUNCTION SOLENOID BODY CONNECTOR VEHICLE HARNESS CONNECTOR 7 8 12 11 12 6 5 4 3 2 1 7 1 6 SOLENOID ASSEMBLY Gasoline Engines Only - Part Number = F81Z-7G391-BA Diesel Engines Only ----- Part Number = F81Z-7G391-AB Copyright © 2004 ATSG Solenoid Connector Pin Identification and Function Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Vehicle Power In For Solenoids (VPWR) Shift Solenoid "B" (2) Ground from PCM Shift Solenoid "A" (1) Ground from PCM Converter Clutch Solenoid Ground from PCM Coast Clutch Solenoid Ground from PCM Not Used Transmission Fluid Temp Sensor Transmission Fluid Temp Sensor (Signal Return) Not Used Not Used Electronic Pressure Control (EPC) Vehicle Power In For EPC Solenoid (VPWR) PCM Connector Pin Gas & Diesel (Cal) Diesel (49 State) 71, 97 71, 97 11 1 6 27 54 28 20 53 37 91 37 91 81 71, 97 81 71, 97 Figure 22 AUTOMATIC TRANSMISSION SERVICE GROUP 27 Technical Service Information 1999 FORD 4R100 Abbreviation Description Abbreviation 4X4L ABS A/C ACCS AP ARPMDES BARO BOO BPA BPP CCS CPP CRUISE DLC DTC DTC CNT DTR EBP Description 4X4 Low Switch Antilock Brake System Air Conditioning Air Conditioning Clutch Status Accelerator Pedal Position Sensor Ancillary Engine Speed Desired Barometric Pressure Sensor Brake ON/OFF Switch Brake Pressure Applied Brake Pedal Position Coast Clutch Solenoid Clutch Pedal Position Cruise Control Mode (Driving) Data Link Connector Diagnostic Trouble Code Diagnostic Trouble Code Count Digital Transmission Range Sensor Exhaust Back Pressure ECT EOT EPC Engine Coolant Temperature Engine Oil Temperature Electronic Pressure Control EPR FUEL PW GPC Exhaust Pressure Regulator Fuel Pulse Width IAT ICP IPR IVS KAM KAPWR KOEO KOEO MAF MAP Abbreviation Description MIL Malfunction Indicator Lamp OCT ADJ OSS PCM PIP RPM SCCS SS1 SS2 SSA SSB SPOUT TCC TCIL TCS TFT TP TSS VPWR VREF VSS WOT Octane Adjust Output Shaft Sensor Powertrain Control Module Profile Ignition Pickup Engine Speed Speed Control Command Switch Shift Solenoid "1" Shift Solenoid "2" Shift Solenoid "A" Shift Solenoid "B" Spark Output Torque Converter Clutch Trans Control Indicator Lamp Transmission Control Switch Transmission Fluid Temperature Throttle Position Sensor Turbine Shaft Speed Sensor Vehicle Power Supply Vehicle Reference Voltage Vehicle Speed Sensor Wide Open Throttle Glow Plug Control Duty Cycle Intake Air Temperature Injector Control Pressure Sensor Injector Pressure Regulator Idle Validation Switch Keep Alive Memory Keep Alive Power Key On Engine Off Key On Engine Running Mass Air Flow Sensor Manifold Absolute Pressure Sensor Figure 23 28 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2005 ATSG Technical Service Information 1999 FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P0102 P0103 P0107 P0108 Description MAF sensor system fails to operate in a normal manner, which may cause a transmission concern. BARO sensor circuit signal higher or lower than expected. Symptom High EPC pressure. Firm shifts and engagements. May flash TCIL. Firm shift feel, late shifts at higher altitudes. P0122 (TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel, Accelerator Pedal Position sensor below abnormal shift schedule, abnormal specification during normal operation. TCC operation or does not engage. P0123 (TP) Throttle Position sensor or (AP) Harsh engagements, firm shift feel, Accelerator Pedal Position sensor above or abnormal shift schedule, abnormal below normal specifications during normal TCC operation or does not engage. operation. P0235 MAP sensor or circuit open, shorted to ground Firm shift feel, late shifts at higher altitudes. or to 5V. P0236 MAP sensor signal higher or lower than Firm shift feel, late shifts at higher expected or no response due to vacuum hose altitudes. circuit damaged, disconnected or restricted. P0237 MAP sensor out of On-Board Diagnostics Rerun On-Board Diagnostics and range. No response during Dynamic Response perform "Goose" test when asked. (Goose) test. P0340 P0341 P0344 (DI) Distributor Ignition circuit concern or Engine will stall or will not run. May (CKP) Crankshaft Position sensor failure. flash TCIL. P0500 P0503 Insufficient or intermittent vehicle speed input Harsh engagements, firm shift feel, from VSS/ABS. abnormal shift pattern, unexpected downshifts may occur at closed throttle, abnormal TCC operation or engages only at WOT. May flash TCIL. (BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage not connected. when brake is applied. P0571 P0703 (BPP) Brake Pedal Position switch failure, or Failed off. TCC will not disengage not connected. when brake is applied. P0705 (DTR) Digital Transmission Range sensor Harsh engagements, firm shift feel. circuit malfunction. May flash TCIL. P0708 (DTR) Digital Transmission Range sensor Slight increase in EPC pressure. circuit malfunction. P0712 TFT sensor circuit grounded, exceeds scale set Harsh engagements, firm shift feel, abnormal shift schedule, abnormal for temperature of 315°F. TCC operation or does not engage. Copyright © 2005 ATSG Figure 24 AUTOMATIC TRANSMISSION SERVICE GROUP 29 Technical Service Information 1999 FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P0713 Description Symptom TFT sensor circuit open, exceeds scale set for TCC and stabilized shift schedule temperature of minus 40°F. may be enabled sooner after cold start. May flash TCIL. P0715 Insufficient input from TSS sensor. Set DTC, Flash TCIL and Flash MIL. P0717 TSS sensor signal intermittent. Set DTC, Flash TCIL. P0718 TSS sensor signal noisy. Set DTC. P0720 Insufficient input from OSS sensor. Set DTC, Flash TCIL and Flash MIL. P0721 OSS sensor signal noisy. Set DTC. P0722 OSS sensor signal intermittent. P0731 Set DTC, Flash TCIL. 1-2 shift error because of SSA, SSB, or internal Improper gear selection depending transmission components. on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P0732 2-3 shift error because of SSA, SSB, or internal Improper gear selection depending on failure mode and transmission transmission components. range selector position. Refer to shift solenoid operation chart. P0733 3-4 shift error because of SSA, SSB, or internal Improper gear selection depending on failure mode and transmission transmission components. range selector position. Refer to shift solenoid operation chart. P0741 The PCM picked up an excessive amount of TCC slippage/erratic or no torque TCC slippage during normal operation. converter clutch operation. Flash TCIL. TCC Solenoid circuit failure. Short Circuit: Engine stalls in "D" or "2" at idle with brake applied. Open Circuit: TCC never engaged. P0743 P0750 SSA circuit failure. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P0755 SSB circuit failure. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. Copyright © 2005 ATSG Figure 25 30 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 1999 FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code Description Symptom P0781 1-2 shift error because of SSA, SSB, or internal Improper gear selection depending on failure mode and transmission transmission components. range selector position. Refer to shift solenoid operation chart. P0782 2-3 shift error because of SSA, SSB, or internal Improper gear selection depending on failure mode and transmission transmission components. range selector position. Refer to shift solenoid operation chart. P0783 3-4 shift error because of SSA, SSB, or internal Improper gear selection depending on failure mode and transmission transmission components. range selector position. Refer to shift solenoid operation chart. P1100 P1101 MAF sensor system fails to operate in a normal High EPC pressure. Firm shifts and manner, which may cause a transmission engagements. May flash TCIL. concern. P1111 System Pass. P1120 Throttle Position Sensor voltage lower than Harsh engagements, firm shift feel, expected. abnormal shift schedule, abnormal TCC operation or does not engage. P1124 Throttle Position Sensor out of On-Board TP sensor (Gas Engines) not at idle position during KOEO test. Diagnostics range during KOEO test. P1280 Injection Control Pressure (ICP) sensor circuit May result in firm shifts. failure (Diesel Engine), or out of range low. P1281 Injection Control Pressure (ICP) sensor circuit May result in firm shifts. failure (Diesel Engine), or out of range high. P1460 P1463 P1464 A/C switch error. P1500 Insufficient or intermittent vehicle speed input Harsh engagements, firm shift feel, from VSS/ABS. abnormal shift pattern, unexpected downshifts may occur at closed throttle, abnormal TCC operation or engages only at WOT. May flash TCIL. No Codes Detected. Failed On: EPC pressure slightly low with A/C off. Failed Off: EPC pressure slightly low with A/C on. Copyright © 2005 ATSG Figure 26 AUTOMATIC TRANSMISSION SERVICE GROUP 31 Technical Service Information 1999 FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P1702 Description Symptom Digital Transmission Range (DTR) sensor Erratic harsh shift engagements. signal intermittent. P1703 (BPP) Brake Pedal Position switch not actuated Failed on or not connected, TCC will not engage at less than one-third during KOER test. throttle opening. P1704 Digital Transmission Range (DTR) sensor Increase in EPC pressure. misaligned or failed electronically. P1705 Digital Transmission Range (DTR) sensor not Rerun On-Board Diagnostics. run in park or neutral during On-Board Diagnostics KOEO or KOER tests. P1711 Transmission not at operating temperature Warm vehicle to normal operating temperature and rerun On-Board during On-Board Diagnostics. Diagnostics. P1713 P1714 No change in TFT sensor - Low range. SSA mechanical failure detected. May flash TCIL. P1715 SSB mechanical failure detected. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. P1718 P1728 No change in TFT sensor - High range. P1729 4X4 Low switch circuit failure. Early or delayed shift schedule. P1740 TCC solenoid mechanical failure detected. Harsh shift, may flash TCIL. P1744 The PCM picked up an excessive amount of TCC slippage/erratic or no torque TCC slippage during normal operation. converter clutch operation. Flash TCIL. P1746 Failure of the EPC control pressure driver Open circuit causes maximum EPC pressure, harsh engagements and located inside the PCM. shifts. May flash TCIL. P1747 EPC shorted circuit failure, or PCM. Improper gear selection depending on failure mode and transmission range selector position. Refer to shift solenoid operation chart. May flash TCIL. Excessive amount of transmission slippage has Transmission slippage, erratic or no TCC operation. May flash TCIL. been detected. Shorted circuit causes minimum EPC pressure, limits engine torque with partial fuel shut off and heavy misfire. Flashing TCIL. Copyright © 2005 ATSG Figure 27 32 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 1999 FORD 4R100 Diagnostic Trouble Code Chart Diagnostic Code P1754 Description Symptom CCS circuit failure. Failed Off: No third gear engine braking in O.D. cancel. Failed On: Third gear emgine braking in O.D. range. Coast clutch may be damaged causing eventual failure. P1760 EPC signal intermittent short. Short circuit causes minimum EPC pressure. P1780 TCS not cycled during the On-Board No overdrive cancel when switch is cycled. Diagnostics or the circuit is open or shorted. P1781 4X4 Low switch circuit failure. P1783 Transmission Fluid Temperature has exceeded Slight increase in EPC pressure. 270°F. May flash TCIL. Early or delayed shift schedule. Copyright © 2005 ATSG Figure 28 AUTOMATIC TRANSMISSION SERVICE GROUP 33 Technical Service Information FORD 4R100 POWER-TAKE-OFF DESCRIPTION AND OPERATION DESCRIPTION: Beginning at the start of production for 1999 models, Ford Motor Company introduced a new 4R100 transmission in some F250, F350, F450 and F550 Super Duty Trucks, equipped with the 5.4L, 6.8L and 7.3L engines. Basically the new 4R100 is a revised version of the previous E4OD transmission with a Power-Take-Off (PTO) window on the left side of the transmission case, right behind the front pump. Refer to Figure 29. The revisions that have occured have created many major engineering changes that have affected many internal and external parts that will create service concerns and diagnostic concerns. PTO REQUIREMENTS: (1) Obviously the case must be PTO capable with the cast-in window in the transmission where the PTO unit mounts to the transmission, as shown in Figure 29. (2) Designed for use during Mobile (Some Models) or Stationary conditions. (3) PTO is available as an option only on 8500 GVW or above, Super Duty F-Series trucks with 6.8L Gasoline and 7.3L Diesel engines. Ford 4R100 transmissions on other models are not PTO capable. (4) Battery voltage must be supplied to the Electronic Engine Control (EEC) input pin 4 on gasoline models, or pin 66 on diesel models, when PTO is engaged. The processor uses this information to raise EPC pressure to approximately 55 PSI so that you do not smoke the coast clutch. This voltage must be provided by the PTO installer. CONDITIONS FOR PTO OPERATION (General): (1) The vehicle is not in the crank or start mode. (2) The transmission range selector must be in P, R, O.D, 2 or 1 position. The PTO will not operate when selector is in the neutral position. (3) PTO operation is inhibited when in cranking mode, neutral, or 4th gear. (4) Transmission only operates 1st through 3rd gears. Computer strategy does not allow 4th gear to engage, even if selected. (5) Transmission Fluid Temperature Sensor reading is up to operating temperature. Continued on Page 36 Copyright © 2005 ATSG 34 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD 4R100 WITH POWER TAKE OFF OPTION Note: PTO is available as an option on 8500 GVW or above, Super Duty F-Series trucks with 6.8L gasoline and 7.3L Diesel engines. Ford 4R100 transmissions on other models are not PTO capable. Ford XW4P-AC RJL-B 004361 17 BD-9C BA -7006- RFF81P 98 d For Year BD- 6520 1 2 3 4 004361 1 2 3 4 9 9=1999 0=2000 1=2001 2=2002 3=2003 4X4 5G XW4P-AC RJL-B 004361 BD-9C17 Build Date Month Day C 17 A=Jan B=Feb C=Mar D=Apr E=May F=Jun G=Jul H=Aug J=Sep K=Oct L=Nov M=Dec Assembly Part Number, Prefix And Suffix Transmission Model Serial Number Build Date (Year, Month, Day) Copyright © 2005 ATSG Figure 29 AUTOMATIC TRANSMISSION SERVICE GROUP 35 Technical Service Information DIESEL ENGINE PTO OPERATION: "AUXILIARY" POWERTRAIN CONTROL MODULE 7.3L DIESEL ENGINE (ONLY) The Auxiliary Powertrain Control Module (APCM) commands the Electronic Engine Control (EEC) module to increase the idle speed during PTO operation. The APCM controls engine speed from 1200 to 2500 RPM. The Auxiliary Powertrain Control Module is a seperate option, it does not come standard with a PTO capable transmission, and is for 7.3L diesel applications only. Intended for stationary use only, and in stationary operation the PTO requires an engine idle speed of 1200 RPM. During stationary PTO operation on the 7.3L diesel, the EEC increases the idle to 1200 RPM automatically. During stationary PTO operation, the Torque Converter Clutch (TCC) engages once the RPM reaches 1200-1300 RPM. The following conditions must be met before the idle speed is increased: 1. 2. 3. 4. 5. Parking brake must be engaged for all applications. No hydraulic brake actuation. Accelerator pedal must be in the idle position. Vehicle speed must be zero MPH. Brake lights must be functional. Ford AUXILIARY POWERTRAIN CONTROL MODULE CHARGE PROTECTION APPLICATION Charge Protection is used for maintaining battery charge. In Charge Protection mode, the battery voltage is monitered and the engine idle speed is increased as necessary, so the battery charge is maintained as required. Charge Protection can be activated from in-cab and can be programmed to activate automatically on engine start-up. Exclusively for light trucks with the 7.3L Diesel Engine. Intended for Stationary Use Only. Order Guide Option Code 961. KITS INCLUDE RPM CONTROL RPM Control is used for RPM Control mode can be activated from in-cab and can be programmed to activate automatically on engine start-up. The programmable speed presets range from 1300 to RPM CONTROL CHARGE PROTECT POWER Ford 2500 Aux. Powertrain Control Module. Mounting Hardware and Bracket. Wiring Harness. Instruction Booklet. Operators Card. LCD screen displays the current engine speed or battery voltage. Each Single Arrow key contains a preset speed allowing for four programmable RPM settings. The Double Arrow keys can also be used to manually raise or lower the engine speed at a faster or slower rate. This is the recommended method of elevating idle speed for PTO operations. Copyright © 2005 ATSG Continued on Page 37 36 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information GASOLINE ENGINE PTO OPERATION: (1) PTO installer must obtain a "High Idle Throttle Control" from an aftermarket source. (2) Auxiliary Powertrain Control Module seen on the previous page, does not work on the gasoline engine models. APCM module works only on the 7.3L diesel engine. (3) For stationary PTO operation, an engine idle speed of 1300 RPM is required. (4) The Torque Converter Clutch (TCC) engages once the engine reaches 1300 RPM. TRANSMISSION FUNCTIONS DURING PTO OPERATION: (1) Shift Solenoid "B" (2) is turned on, the coast clutch activates and does not allow 4th gear operation during PTO operation. (2) The Electronic Pressure Control (EPC) pressure is raised to approximately 55 PSI. This is why the coast clutch will be smoked in a short period of time if the battery voltage wire is not applied to EEC input pin 4 (gasoline) or pin 66 (diesel) when the PTO is engaged. (3) The Transmission Control Indicator Lamp (TCIL) illuminates. (4) When the PTO is turned ON, the transmission operates only in 1st through 3rd gears. Overdrive 4th gear is not allowed by the strategy. (5) The transmission shift schedule is early and shift feel is very firm. DIAGNOSIS CONCERNS WITH PTO EQUIPPED VEHICLES: (1) Always ensure that PTO is turned OFF, before any diagnosis procedures begin. (2) Never perform any transmission special tests (i.e. pressure test, stall test etc.) when the PTO is turned ON. (3) If a transmission concern or symptom goes away with the PTO turned OFF, it is most likely not a transmission concern. (4) On Board Diagnostics operate normally during PTO operation with the exception of the engine misfire moniter. The circuit checks made by the PCM and Failure Mode Effect Management (FMEM) capability will continue. The PTO must be turned OFF to access Diagnostic Trouble Codes (DTC's) and perform OBD tests. (5) No testing with the PTO turned ON. Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 37 Technical Service Information FORD 4R100 "NON-PTO" AND "PTO" HYDRAULIC DIFFERENCES CHANGE: Begining at the start of production for 1999 models, Ford Motor Company made available a "Power Take Off" option for some F250, F350, F450 and F550 Super Duty Trucks, equipped with 5.4L, 6.8L and 7.3L engines. REASON: The "PTO" option addition, to the 4R100, required many changes to the transmission to make the "PTO" function. The "PTO" window, added to the case, the "PTO" drive gear and other cosmetic changes were previously covered in this manual. Hydraulic changes also had to be made to make the coast clutch operate in ranges other than the Drive ranges. PARTS AFFECTED: (1) TRANSMISSION CASE: The transmission case was changed to acommodate the "PTO" window, as previously shown in this manual. All 4R100 Cases, "NON-PTO"and "PTO,"also had a "Dam" added to seperate "Rear Lube" and to incorporate "Central Lube"as shown in Figure 30. (2) VALVE BODY TO CASE SPACER PLATE: The Valve Body to Case Spacer plate on the "PTO" versions had a hole added, to supply the 3-4 Shift Valve with Line Pressure, as shown in Figure 32. A hole was also added to the Spacer Plate on "NON-PTO" and "PTO" versions to connect "Solenoid Regulator Valve" oil to supply "Central Lubrication." Refer to Figures 31 and 32 for identification of "NON-PTO"and "PTO" Valve Body To Case Spacer Plates. (3) MAIN VALVE BODY: A passage was added on the "Upper Side" of the Main Valve Body on "PTO" versions, as shown in Figure 34, to supply Line Pressure to the 3-4 Shift Valve. A passage was also added, on the "Lower Side" of the Main Valve Body, to connect the 3-4 Shift Valve (Coast Clutch Circuit) to an exhaust as shown in Figure 36. The spring side of the 3-4 Shift Valve was also seperated from the Low/Reverse circuit as shown in Figure 36. Refer to Figures 33 thru 36 for identification of "NON-PTO" and "PTO" Main Valvebody's. (4) LOWER VALVE BODY: The Lower Valve Body had a passage added, as shown in Figure 38, to connect to the "new"exhaust passage in the Main Valve Body. Refer to Figures 37 and 38 for identification of "NON-PTO" and "PTO" Lower Valvebody's. (5) LOWER VALVE BODY SPACER PLATE: The Lower Valve Body Spacer Plate had a hole added to connect the "new" exhaust passage in the Main Valve Body to the "new" exhaust passage in the Lower Valve body, as shown in Figure 39. Refer to Figure 39 for "NON-PTO" and "PTO" Lower Valve Body Spacer Plate identification. INTERCHANGEABILITY: None of the parts listed above will interchange between "NON-PTO" and "PTO" versions. SERVICE INFORMATION: Valve Body To Case Spacer Plate (Non-PTO) .................. ................................F81Z-7A008-DA Valve Body To Case Spacer Plate (PTO) ...........................................................F81Z-7A008-BA Partial Hydraulic Schematic is provided for you in Figure 40 on Page 49. Copyright © 2005 ATSG 38 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 CASE "NON-PTO" AND "PTO" ADDED OIL DAM CENTRAL LUBE REAR LUBE Copyright © 2005 ATSG Figure 30 AUTOMATIC TRANSMISSION SERVICE GROUP 39 Technical Service Information 97 12 4R100 MAIN SPACER PLATE "NON-PTO" I.D.- 1 DOVE TAIL PART NUMBER F81Z-7A008-DA F81P-DA CENTRAL LUBE ORIFICE Copyright © 2005 ATSG Figure 31 40 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 98 6 4R100 MAIN SPACER PLATE "PTO" CENTRAL LUBE ORIFICE I.D.- 2 DOVE TAIL PART NUMBER F81Z-7A008-BA F81P-BA ADDED MAIN LINE PRESSURE HOLE FROM PRESSURE REGULATOR VALVE Copyright © 2005 ATSG Figure 32 AUTOMATIC TRANSMISSION SERVICE GROUP 41 Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" Copyright © 2005 ATSG Figure 33 42 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "PTO" PASSAGE ADDED TO FEED LINE PRESSURE TO THE 3-4 SHIFT VALVE Copyright © 2005 ATSG Figure 34 AUTOMATIC TRANSMISSION SERVICE GROUP 43 Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" RFF61P7A092-AB 6 Ford 09328 Du Page I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" LOW/REVERSE CLUTCH Copyright © 2005 ATSG Figure 35 44 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "PTO" P RFF81P7A092-AA 1 Ford 19538 Du Page I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" PASSAGE ADDED LEADING TO THE EXHAUST IN THE LOWER VALVE BODY LOW/REVERSE PASSAGE RE-MOVED FROM SPRING SIDE OF 3-4 SHIFT VALVE LOW/REVERSE CLUTCH Copyright © 2005 ATSG Figure 36 AUTOMATIC TRANSMISSION SERVICE GROUP 45 Technical Service Information 5 Du Page Ford RFF61P-7A101 A 4R100 LOWER VALVE BODY "NON-PTO" 09828 I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" Copyright © 2005 ATSG Figure 37 46 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" 14018 1 EXHAUST PASSAGE ADDED FROM COAST CLUTCH VALVE TO 3-4 SHIFT VALVE DUPAGE P Ford RFF81P-7A101 AA 4R100 LOWER VALVE BODY "PTO" Copyright © 2005 ATSG Figure 38 AUTOMATIC TRANSMISSION SERVICE GROUP 47 Technical Service Information 4R100 LOWER VALVE BODY SPACER PLATE 4R100 "NON-PTO" 4R100 "PTO" I.D.- 1 DOVE TAIL I.D.- 2 DOVE TAIL HOLE ADDED TO CONNECT WITH EXHAUST PASSAGE IN LOWER VALVE BODY Copyright © 2005 ATSG Figure 39 48 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "NON-PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT FROM SOLENOID 4 COAST CLUTCH SOLENOID FROM SOLENOID 2 LINE PRESSURE FROM MANUAL VALVE "OD CIRCUIT" TO CB3/COAST CLUTCH LINE PRESSURE FROM MANUAL VALVE "REVERSE" COAST CLUTCH SHIFT VALVE 3-4 SHIFT VALVE TO CB7/OVERDRIVE CLUTCH FROM 2-3 SHIFT VALVE FROM CB15 / 2-3 SHIFT VALVE X "PTO" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT FROM SOLENOID 4 COAST CLUTCH SOLENOID FROM SOLENOID 2 TO CB3/COAST CLUTCH LINE PRESSURE FROM PRESSURE REGULATOR VALVE FIGURE 34 FIGURE 36 COAST CLUTCH SHIFT VALVE 3-4 SHIFT VALVE TO CB7/OVERDRIVE CLUTCH FROM 2-3 SHIFT VALVE FIGURE 38 X X Copyright © 2005 ATSG Figure 40 AUTOMATIC TRANSMISSION SERVICE GROUP 49 Technical Service Information FORD 4R100 "PWM" AND "NON-PWM" PUMP DIFFERENCES CHANGE: Beginning at the start of production in 1999, the 4R100 transmission was offered with two different torque converter clutch application strategies. A "PWM" (Pulse Width Modulated) version, was added in V-10 gas powered vehicles and all diesel, and a "NON-PWM" version, offered in all other gas powered vehicles. This required two different solenoid packs as well as two different pump assemblies. REASON: For smooth converter apply on V-10 gas and diesel engine models. PARTS AFFECTED: (1) PUMP ASSEMBLY: • The pump cover assembly had the rear of the Converter Clutch Valve bore enlarged approximately .070" to acommodate the enlarged land of the Converter Clutch Valve, as shown in Figure 41. A .036" orifice and an air bleed were added to the TCC Solenoid signal passage, as shown in Figure • 43. The Converter Clutch Control Valve's rear spool was enlarged approximately .070". There was • also a bushing and valve added to the end of the valve train, as shown in Figure 41. A hole was added to the pump cover to connect the Converter Clutch Control Valve Bushing to • Converter Regulator Valve oil, as shown in Figure 43. The Converter release orifice in the NON-PWM pump cover, as shown in Figure 42, was removed • from the PWM pump cover, as shown in Figure 43. Refer to Figure 44 for the NON-PWM pump hydraulic circuit. Refer to Figure 45 for the PWM pump hydraulic circuit with all hydraulic changes shown. SOLENOID PACK: The PWM solenoid pack requires a Pulse Width Modulated torque converter clutch solenoid and (2) the NON-PWM solenoid pack requires an on-off torque converter clutch solenoid. • Refer to Figure 46 to identify the differences between the two solenoid packs. INTERCHANGABILITY: None of the parts listed above are interchangable from model to model. SERVICE INFORMATION: "NON-PWM" Pump assy. (with "Cast Iron" coast clutch drum)...................... F81Z-7A103-AA "NON-PWM" Pump assy. (with "Stamped Steel" coast clutch drum).............. F81Z-7A103-BA "PWM" Pump assy. (with "Stamped Steel" coast clutch drum)........................ F81Z-7A103-CA "NON-PWM" Solenoid Pack........................................................................... F81Z-7G391-BA "PWM" Solenoid Pack..................................................................................... F81Z-7G391-AB Copyright © 2005 ATSG 50 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information CONVERTER CLUTCH CONTROL VALVE "NON-PWM" "PWM" .530" .600" .485" .545" THE DIAMETER AND THE LENGTH OF THE SPOOL ON THE VALVE LAND SHOWN ABOVE, WERE INCREASED ON PWM VERSIONS. THE BORE IN THE PUMP WAS ALSO ENLARGED APPROXIMATELY .070" TO ACOMMODATE THE CHANGES IN THE DIAMETER OF THE VALVE Copyright © 2004 2005 ATSG Figure 41 AUTOMATIC TRANSMISSION SERVICE GROUP 51 Technical Service Information 4R100 "NON-PWM" PUMP COVER ASSEMBLY CONVERTER CLUTCH CONTROL VALVE CONVERTER REGULATOR VALVE PRESSURE REGULATOR VALVE CONVERTER RELEASE ORIFICE .070" RETAINER LUBE ORIFICE .090" Copyright © 2005 ATSG Figure 42 52 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 "PWM" PUMP COVER ASSEMBLY CONVERTER CLUTCH CONTROL VALVE CONVERTER REGULATOR VALVE HOLE ADDED TO CONNECT TO HOLE IN CONTROL VALVE BUSHING PRESSURE REGULATOR VALVE CONVERTER RELEASE ORIFICE OMITTED RETAINER LUBE ORIFICE .090" ADDED ORIFICE IN TCC PWM SOLENOID SIGNAL PASSAGE .036" ADDED AIR BLEED Copyright © 2005 ATSG Figure 43 AUTOMATIC TRANSMISSION SERVICE GROUP 53 Technical Service Information 4R100 "NON-PWM" PUMP HYDRAULIC CIRCUIT CONVERTER REGULATOR VALVE AIR BLEED CONVERTER CLUTCH CONTROL VALVE MAIN REGULATOR VALVE BALANCE ORIFICE .030" TCC EXHAUST ORIFICE .070" LUBE LUBE ORIFICE .090" BALANCE ORIFICE .030" EPC SIGNAL REVERSE MAIN LINE TCC SOLENOID SIGNAL TO SUMP TO COAST CLUTCH Copyright © 2005 ATSG Figure 44 54 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 "PWM" PUMP HYDRAULIC CIRCUIT .062" ORIFICE IN SLEEVE CONVERTER REGULATOR VALVE AIR BLEED CONVERTER CLUTCH CONTROL VALVE MAIN REGULATOR VALVE BALANCE ORIFICE .030" TCC EXHAUST ORIFICE OMITTED CONVERTER REG. OIL CONNECTION LUBE LUBE ORIFICE .090" ADDED AIR BLEED BALANCE ORIFICE .030" EPC SIGNAL REVERSE MAIN LINE TCC PWM SOLENOID SIGNAL ADDED TO .036" ORIFICE IN TCC PWM SOLENOID SIGNAL SUMP TO COAST CLUTCH Copyright © 2005 ATSG Figure 45 AUTOMATIC TRANSMISSION SERVICE GROUP 55 Technical Service Information FORD 4R100 SOLENOID RESISTANCE CHARTS Solenoid Resistance Chart Solenoid Body Solenoid Pin Numbers Shift Solenoid "B" (2) Shift Solenoid "A" (1) TCC Solenoid, On-Off (NON-PWM) TCC Solenoid, Diesel & V10 (PWM) Coast Clutch Solenoid Electronic Pressure Control Solenoid Transmission Fluid Temp Sensor 1 and 2 1 and 3 1 and 4 1 and 4 1 and 5 11 and 12 7 and 8 Resistance 20-30 Ohms 20-30 Ohms 20-30 Ohms 10-20 Ohms 20-30 Ohms 3.0-5.0 Ohms Variable SOLENOID BODY CONNECTOR 7 8 11 12 6 5 4 3 2 1 SOLENOID ASSEMBLY "NON-PWM" versions - Part Number = F81Z-7G391-BA "PWM" versions ----- Part Number = F81Z-7G391-AB Copyright © 2005 ATSG Figure 46 56 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD E4OD/4R100 NEW DESIGN 6 PINION FORWARD AND REVERSE PLANETARY CARRIER CHANGE: Beginning at the start of production for all 1998 model E4OD transmissions, some models will be equipped with a new design 6 pinion forward planetary carrier (See Figure 47), and a new design 6 pinion reverse planetary carrier (See Figure 48). REASON: Increased torque carrying capacity and increased planetary carrier durability. PARTS AFFECTED: (1) FORWARD PLANETARY CARRIER - Now has 6 pinions instead of the previous 4 pinions for increased torque carrying capacity and increased durability (See Figure 47). (2) REVERSE PLANETARY CARRIER - Now has 6 pinions instead of the previous 4 pinions for increased torque carrying capacity and increased durability (See Figure 48). INTERCHANGEABILITY: The new design forward planetary carrier will back service all models of the E4OD, but it does require the latest design forward ring gear hub and bearing assembly, as there are no holes for the previous design thrust washer (See Figure 47). The new design reverse planetary carrier will back service all models of the E4OD, but it does require the latest design reverse clutch hub and three tang thrust washer for both sides, of the planetary carrier as shown in Figure 48. SERVICE INFORMATION: Forward Planetary Carrier (6 Pinion) .............................................................. F81Z-7A398-CA Reverse Planetary Carrier (6 Pinion) .............................................................. F81Z-7D006-AA Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 57 Technical Service Information NEW DESIGN 6 PINION FORWARD PLANETARY CARRIER PART NUMBER F81Z-7A398-CA Copyright © 2005 ATSG Figure 47 58 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information NEW DESIGN 6 PINION REVERSE PLANETARY CARRIER PART NUMBER F81Z-7D006-AA Front View Rear View REQUIRES 1997-UP DESIGN LEVEL REVERSE CLUTCH HUB ASSEMBLY REQUIRES 3 TANG THRUST WASHERS ON BOTH SIDES OF REAR CARRIER PART NUMBER F0TZ-7A166-D Copyright © 2005 ATSG Figure 48 AUTOMATIC TRANSMISSION SERVICE GROUP 59 Technical Service Information FORD E4OD/4R100 NEW DESIGN SUN SHELL CHANGE: There is now a new design Sun Shell with "Tabs" added to the center of the sun shell slots, as shown in Figure 49, implemented by Ford Motor Co. as a running change, during the 2000 model year. This change eliminated the need for the number 8 thrust washer between the forward and direct drums. REASON: Main reason for this change was cost savings and ease of assembly. PARTS AFFECTED: (1) INPUT SUN SHELL - New design have "Tabs" added to the center of the sun shell slots, as shown in Figure 49, which now support the direct drum for the required clearance between the direct and forward clutch housings, and allows elimination of the number 8 thrust washer, as shown in Figure 50. (2) DIRECT CLUTCH HOUSING - Manufactured "Without" slots in the center hub, as they were no longer needed to accept the number 8 thrust washer tabs. Both design direct drums are illustrated in Figure 50, and cut-away in Figure 51. (3) NUMBER 8 THRUST WASHER - Eliminated (See Figure 50 and 51). INTERCHANGEABILITY: The 1st design Sun Shell is no longer available from Ford Motor Co, as the 2nd design Sun Shell will retro-fit back on all models, with or without the number 8 thrust washer. The 2nd design Direct Clutch Housing (No Slots For Washer) must be used with the 2nd design Sun Shell, as there are no accommodations for the number 8 thrust washer. Refer to "Service Information" below for current OEM part numbers. SERVICE INFORMATION: Direct Clutch Housing, 2nd Design (Without 4 Tab Washer) ......................... YC3Z-7D044-BA Direct Clutch Housing, 1st Design (With 4 Tab Washer) ................................ F81Z-7D044-BA Sun Shell, Hardened, 2nd Design ................................................................... YC3Z-7D064-BA Sun Shell, Regular, 2nd Design ...................................................................... YC3Z-7D064-AA Direct to Forward Drum (No. 8) 4 Tab Thrust Washer ...................................... E9TZ-7C096-A Copyright © 2005 ATSG 60 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PREVIOUS DESIGN SUN SHELL "No Longer Available From Ford" NEW DESIGN SUN SHELL Hardened = YC3Z-7D064-BA Regular = YC3Z-7D064-AA Added "Tabs" May Be Used With "ONLY" The Previous Design Direct Drum And Requires The No. 8 Washer (See Figure 50) May Be Used With Both Design Direct Drums With Or Without Washer (See Figure 50) Copyright © 2005 ATSG Figure 49 AUTOMATIC TRANSMISSION SERVICE GROUP 61 Technical Service Information NEW DESIGN DIRECT CLUTCH DRUM "WITHOUT" SLOTS FOR THE NUMBER 8 THRUST WASHER PART NO. YC3Z-7D044-BA PREVIOUS DESIGN DIRECT CLUTCH DRUM "WITH" SLOTS FOR THE NUMBER 8 THRUST WASHER PART NO. F81Z-7D044-BA Number 8 Thrust Washer E9TZ-7C096-A No Slots For Number 8 Thrust Washer Slots For Number 8 Thrust Washer May Be Used With Both Design Sun Shells (See Figure 49) May Be Used With "ONLY" The New Design Sun Shell (See Figure 49) Copyright © 2005 ATSG Figure 50 62 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PREVIOUS DESIGN DIRECT CLUTCH DRUM "WITH" SLOTS FOR THE NUMBER 8 THRUST WASHER AND PREVIOUS SUNSHELL NEW DESIGN DIRECT CLUTCH DRUM "WITHOUT" SLOTS FOR THE NUMBER 8 THRUST WASHER AND NEW SUNSHELL When Direct Clutch Housing Is Supported By The "Added" Raised Tabs Here, When Direct Clutch Housing Is Not Supported Here, The Number 8 Thrust Washer Is Required The Number 8 Thrust Washer Is Not Required Copyright © 2005 ATSG Figure 51 AUTOMATIC TRANSMISSION SERVICE GROUP 63 Technical Service Information INTERMEDIATE FORD "DIODE"4R100 FREEWHEEL FAILURE COMPLAINT: Some Ford Motor Company vehicles equipped with the 4R100 transmission may exhibit premature failure of the newly introduced Intermediate "Diode" Freewheel device that was installed in model year 2001 and illustrated in Figure 52. CAUSE: The cause may be, more than expected load factors. CORRECTION: The Intermediate "Diode" is no longer serviced by Ford Motor Company. The part number now supercedes to all of the previous design level parts, which include the direct clutch housing, intermediate sprag assembly, outer race to direct drum thrust washer, and the intermediate friction plates. All of the previous design level parts are illustrated in Figure 53, with the OEM part numbers. The intermediate frictions must be replaced because the tooth count on the outer race between the diode and the sprag are different. Special Note: ATSG recommends replacing the Intermediate "Diode" during service, even if it has not yet failed, to protect yourself from possible future failures. SERVICE INFORMATION: Direct Clutch Housing, 2nd Design (Without 4 Tab Washer) ................ YC3Z-7D044-BA Direct Clutch Housing, 1st Design (With 4 Tab Washer) ....................... F81Z-7D044-BA Sun Shell, Hardened, 2nd Design .......................................................... YC3Z-7D064-BA Sun Shell, Regular, 2nd Design ............................................................. YC3Z-7D064-BA Direct to Forward Drum 4 Tab Thrust Washer ....................................... E9TZ-7C096-A Direct Drum to Outer Sprag Race Thrust Washer .................................. E9TZ-7G401-A Intermediate Sprag Assembly ................................................................. E9TZ-7A089-B Intermediate Friction Plates (Special 50 Tooth, 3 Required) .................. 1C3Z-7B164-BA 4R100 INTERMEDIATE "DIODE" No Longer Available For Service Copyright © 2005 ATSG Figure 52 64 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PARTS NEEDED TO REPLACE INTERMEDIATE DIODE Intermediate Friction Plates Part Number 1C3Z-7B164-BA (Or Raybestos Plates OK) (3 Required) Outer Race To Drum Thrust Washer Part Number E9TZ-7G401-A Intermediate Sprag Assembly Part Number E9TZ-7A089-B Direct Clutch Housing Part No. YC3Z-7D044-BA (No Washer) Part No. F81Z-7D044-BA (With Washer) 4 Tab Thrust Washer Part Number E9TZ-7C096-A Copyright © 2005 ATSG Figure 53 AUTOMATIC TRANSMISSION SERVICE GROUP 65 Technical Service Information FORD 4R100 HYDRAULIC PASSAGE IDENTIFICATION The following pages provide you with hydraulic passage identification in Figure 55 through Figure 64 for the transmission case, all valve bodies and all oil pump configurations. The legend for the abbreviations is found in Figure 54. PASSAGE IDENTIFICATION LEGEND 1-R = 1st-Reverse 1-R/M2 = 1st-Reverse/Manual 2 C-CL = Coast Clutch CONV = Converter D-CL = Direct Clutch EPC = Electronic Pressure Control EX = Exhaust F-CL = Forward Clutch INT-CL = Intermediate Clutch L/R-CL = Low/Reverse Clutch M123/R = Manual 1, 2, 3/Reverse OD = Overdrive OD234 = Overdrive 2nd, 3rd, 4th OD34/R = Overdrive 3rd, 4th/Reverse PRN1 = Park, Reverse, Neutral, 1st PRN1/M2 = Park, Reverse, Neutral, 1st/Manual 2 R/1 = Reverse/1st R/M2 = Reverse/Manual 2 R/M2/S2 = Reverse/Manual 2/Solenoid 2 R = Reverse S1 = Solenoid 1 S2 = Solenoid 2 S3 = Solenoid 3 S4 = Solenoid 4 S4/1-R/M2 = Solenoid 4/1st-Reverse/Manual 2 SRV = Solenoid Regulator Valve Copyright © 2005 ATSG Figure 54 66 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 CASE PASSAGE IDENTIFICATION "PTO AND NON-PTO" EPC REV C CL EX S3 LINE LINE L-MOD INT-CL SRV OD-CL ID VO -CL LINE 4 SRV D-CL REV C EP OD234 S-4 OD-CL C-CL REV OD S4 SRV OD L- M INT-C L O D EPC D-CL LINE F-CL LUBE S4 4 S-1 OD S-1 SRV INT VO ER S T- IN CENT-LUBE F-CL VO SER INT SERVO M123/R REV M1 R/1 R/M2 S4/1 R/M2 OD34/R SRV REV S3 OD4 REV 1-R/M2 S1 1-R/M2 S2 S2 SRV PRN 1/X S4 LINE EX R/M2/S2 M1 EX SOLENOID CONNECTOR 1-R EX OD EX OD 1-R L/R CL LINE CENT-LUBE EPC 2 EX /M N1 PR EX REAR-LUBE EPC LIMIT BALL AND SPRING REV Copyright © 2005 ATSG Figure 55 AUTOMATIC TRANSMISSION SERVICE GROUP 67 Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" MODELS ONLY VOID VOID VOID VOID SRV REV SRV REV EX S4 OD4 F-CL LINE S-1 OD123/R M123/R C-CL F-CL EX SRV INT-CL 1-R/M2 OD234 SRV 1-R/M2 S4 S4/1-R/M2 S-1 EX REV C-CL PRN1/M2 PRN1/X PRN1/M2 INT-SERVO 1-R/M2 EX 1-R/M2 PRN1 PRN1 S-2 LINE S-1 1-R OD34/R REV OD4 S-2 OD123/R M2 S-1 S-2 M2/S2/R M2/S2/R LINE PRN1/M2 REV REV OD EX LINE OD PRN1/X OD PRN1/M2 OD/R/M2/M1 REV L/R-CL L/R-CL OD4 LINE REV 1-R EX OD34/R REV LINE PRN1/M2 EPC 1-R REV VOID VOID Copyright © 2005 ATSG Figure 56 68 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "UPPER SIDE" 4R100 MAIN VALVE BODY "PTO" MODELS ONLY VOID VOID VOID VOID SRV SRV REV REV EX S-4 OD4 F-CL LINE S-1 OD123/R M123/R C-CL F-CL EX SRV INT-CL 1-R/M2 OD234 1-R/M2 SRV EX REV C-CL S-4 S4/1-R/M2 S-1 PRN1/M2 PRN1/X PRN1 PRN1/M2 INT-SERVO 1-R/M2 EX 1-R/M2 PRN1 PRN1 S-2 LINE S-1 1-R PASSAGE ADDED TO FEED LINE PRESSURE TO THE 3-4 SHIFT VALVE OD34/R REV OD4 S-2 OD123/R M2 S-1 S-2 M2/S2/R M2/S2/R LINE PRN1/M2 REV OD123/R OD EX LINE LINE LINE LINE PRN1/X PRN1/M2 OD/R/M2/M1 REV L/R-CL L/R-CL VOID OD34/R EX REV EX REV EX 1-R PRN1/M2 EPC 1-R REV VOID VOID Copyright © 2005 ATSG Figure 57 AUTOMATIC TRANSMISSION SERVICE GROUP 69 Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "NON-PTO" MODELS ONLY VOID OD234 REV F-CL F-CL RFF61P7A092-AB REV EX EX 6 Ford F-CL PRN1 PRN1 OD34/R M2/S2/X 09328 Du Page PRN1/M2 I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" OD4 PRN1/M2 OD 123/R S2 REV M2 M2/S2/R M2/S2 REV EX OD4 L/R-CL OD123/R F-CL OD34/R REV EX EPC L/R-CL Copyright © 2005 ATSG Figure 58 70 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "LOWER SIDE" 4R100 MAIN VALVE BODY "PTO" MODELS ONLY VOID OD234 REV F-CL P F-CL RFF81P7A092-AA EX REV EX 1 Ford F-CL PRN1 OD34/R M2/S2/X 19538 Du Page PRN1 I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" OD4 PRN1/M2 OD 123/R S2 F-CL PASSAGE ADDED LEADING TO THE EXHAUST IN THE LOWER VALVE BODY REV M2 M2/S2/R M2/S2 EX REV EX OD4 L/R-CL OD123/R F-CL LOW/REVERSE PASSAGE RE-MOVED FROM SPRING SIDE OF 3-4 SHIFT VALVE OD34/R REV EX EPC L/R-CL Copyright © 2005 ATSG Figure 59 AUTOMATIC TRANSMISSION SERVICE GROUP 71 Technical Service Information 4R100 LOWER VALVE BODY "NON-PTO" MODELS ONLY REV RFF61P-7A101 A M2/S2 Ford M2/S2/X EX OD34/R L/R-CL REV VOID EPC REV M2 S2 OD123/R EPC Du Page OD34/R REV 5 PRN1 EX I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" 09828 EPC REV REV F-CL F-CL F-CL REV OD234 VOID Copyright © 2005 ATSG Figure 60 72 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 LOWER VALVE BODY "PTO" MODELS ONLY REV REV RFF81P-7A101 AA EX Ford EX OD34/R L/R-CL M2/S2/X VOID EPC REV M2/S2 M2 S2 P OD123/R EPC OD34/R EX 1 EXHAUST PASSAGE ADDED FROM COAST CLUTCH VALVE TO 3-4 SHIFT VALVE PRN1 DUPAGE REV I.D.-ROUGH FORGING NUMBER OF "RF-F8" WHICH INDICATES "98" REV REV F-CL 14018 EPC F-CL F-CL REV OD234 VOID Copyright © 2005 ATSG Figure 61 AUTOMATIC TRANSMISSION SERVICE GROUP 73 Technical Service Information 4R100 PUMP COVER ASSEMBLY "NON-PWM" MODELS ONLY VOID VENT VENT EPC LINE REV LINE EPC CONV REV VOID CONV REV CONV CONV CONV VOID EX CONV LUBE-TO COOLER EX LINE CONV CONV LINE CONV VOID LINE S3 EX LINE S3 LINE SUCTION SUCTION VOID EPC LINE VOID REV S3 VOID Copyright © 2005 ATSG Figure 62 74 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 PUMP COVER ASSEMBLY "PWM" MODELS ONLY HOLE ADDED TO CONNECT TO HOLE IN CONTROL VALVE BUSHING VOID CONVERTER RELEASE ORIFICE OMITTED VENT VENT EPC CONV LINE REV EPC CONV REV VOID LINE REV CONV CONV CONV LUBE-TO COOLER CONV VOID EX EX LINE CONV LINE VOID LINE CONV LINE EX S3 LINE SUCTION SUCTION VOID EPC LINE REV VOID S3 LUBE ORIFICE .090" ADDED ORIFICE IN TCC PWM SOLENOID SIGNAL PASSAGE .036" ADDED AIR BLEED Copyright © 2005 ATSG Figure 63 AUTOMATIC TRANSMISSION SERVICE GROUP 75 Technical Service Information 4R100 PUMP BODY "PWM" AND "NON-PWM" VENT EPC VOID VENT EPC LINE REV CONV LINE CONV REV REV LINE CONV LINE LINE CONV LINE NE LI VOID CONV CONV VOID SUCTION EX SUCTION EX SUCTION LINE EPC LINE V LINE SUCTION RE LINE Copyright © 2005 ATSG Figure 64 76 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information FORD MOTOR COMPANY TRUCKS 1996 AND LATER NO TORQUE CONVERTER CLUTCH APPLICATION AT LESS THAN 30 PERCENT THROTTLE COMPLAINT: Some Ford Motor Company Trucks, 1996 and later, may exhibit a no Torque Converter Clutch application at less than 30 percent throttle. No Trouble Codes present. CAUSE NO. 1: One cause for this condition may be that one or more of the vehicle brake light bulbs, including the High Mount brake light may be burned out, or have a damaged filament (See Figure 65). When this condition is present, the PCM will detect an open in the brake lamp circuit, and due to a pull-up resistor in the PCM, will output voltage from PCM terminal 92 to the brake on-off switch (See Figure 66). As a result, the Torque Converter Clutch will not be applied at less than 30 percent throttle. CAUSE NO. 2: Recently there has been an increase in the popularity of replacing the stock incandescent brake lamp bulbs, with aftermarket LED lamp assemblies. Refer to Figures 67 and 68. The main advantages of switching to LED lamp assemblies is that there are no fragile filaments to burn out or break, which means that the LED lamp assemblies may possibly last for the entire life of the vehicle, and LED lamps consume much less energy than the stock incandescent bulbs. Due to the low power consumption, the PCM may view this reduced current draw as being a burned out bulb, resulting in a no Torque Converter Clutch apply at less than 30 percent throttle. CORRECTION NO. 1: Prior to any part replacement or modifications, it would be recommended to check for a 5 to 8 volt DC signal coming out of the PCM at terminal 92 using a volt meter set to read DC voltage. Voltage may also be checked at the Light Green wire located at the back of the Brake On-Off Switch. Note: The example given is for a 1996 F-Series 7.3 Diesel. This test will help to confirm that a circuit fault has been detected by the PCM. Refer to Figure 66. Normal operation will be 0 volts DC, brake off, and 12 volts DC, brake on. Replace any burned out brake lamp bulbs, including the High Mount brake lamp bulb, as shown in Figure 65. It is also important to note, that a bad ground for the rear lamp assembly, has also been known to cause the identical symptom. Refer to Figure 69 for the rear lamp assemblies ground location. CORRECTION NO. 2: For those vehicles that have had the stock incandescent bulbs replaced with aftermarket LED bulb assemblies, it may be necessary to install a 6 ohm- 50 watt Load Resistor across the brake light power wire to simulate the load of the regular stock incandescent bulb (See Figure 70). Note: One resistor is required for use on each LED bulb assembly. The 6 ohm, 50 watt Load Resistors are available from the suppliers of the LED bulb assemblies. Two examples are "superbrightleds.com" and "digikey.com". Cost of the resistor is approximately five dollars U.S. Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 77 Technical Service Information HIGH MOUNT STOP LAMP 30 20 40 50 60 70 10 00 MISS I OUR 44-K 04 OCT LEFT AND REAR STOP LAMP ASSEMBLIES Copyright © 2005 ATSG Figure 65 Note: Example given is for a 1996 F Series 7.3 Diesel Ford EEC 5 PCM Terminal Identification 1 27 53 79 13 39 65 91 14 40 66 92 26 52 78 104 Light Green Wire Malfunction:Check for 5 to 8 volts DC at PCM pin 92 or at the Light Green wire at the Brake On-Off Switch BRAKE ON-OFF SWITCH Normal Operation: 0 volts DC brake off 12 volts DC brake on Copyright © 2005 ATSG Figure 66 78 AUTOMATIC TRANSMISSION SERVICE GROUP WAGNER 12V 3157 Technical Service Information AFTERMARKET LED BULB FACTORY STYLE INCANDESCENT BULB Copyright © 2005 ATSG Figure 67 Copyright © 2005 ATSG Figure 68 GROUND LOCATION T FRON TYPICAL TAIL LIGHT GROUND LOCATION Copyright © 2005 ATSG Figure 69 AUTOMATIC TRANSMISSION SERVICE GROUP 79 Technical Service Information LOAD RESISTOR INSTALLATION FROM BRAKE ON-OFF SWITCH SPLICE INTO BRAKE LAMP POWER WIRE TO GROUND 6 OHM, 50 WATT LOAD RESISTOR LED BULB Copyright © 2005 ATSG Figure 70 80 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information Notes Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 81 Technical Service Information FORD E4OD/4R100 NEW "SPECIAL" CASE ASSEMBLY FROM FORD MOTOR CO. CHANGE: Currently, the "only" new case available from Ford Motor Company, for replacement in any E4OD equipped vehicles, is a modified 4R100 case. Ford has machined out the dam in the case that seperates center and rear lube, near the rear of the case, as shown in Figure 71. CAUTION: This case requires special main spacer plate, spacer plate gaskets, speed sensor plugs and extension housing, that do not come with the new case from Ford Motor Company. We have provided you with a list of additional parts that will be required to use this case, under "Parts Affected", depending on the model year that you are repairing. The older the unit, the more parts required. REASON: Cost savings due to not having to maintain seperate dies for the case assemblies. PARTS AFFECTED: REQUIREMENTS FOR 1996 THRU 1998 MODELS ONLY: (1) SPACER PLATE - Ford Motor Co. part number F81Z-7A008-EA or F8UZ-7A008-CA, as shown in Figure 72. (2) CASE TO SPACER PLATE GASKET - Ford Motor Co. part number F81Z-7C155-AA, with "White" stripe for identification, as shown in Figure 73. (3) SPACER PLATE TO V.B. GASKET - Ford Motor Co. part number F81Z-7D100-AB, with "Blue" stripe for identification, as shown in Figure 73. (4) COOLER BYPASS ASSEMBLY - Ford Motor Co. part number F81Z-7H322-AA for 1996 models only, as shown in Figure 74. 1997 and 1998 models came with cooler bypass. (5) SPEED SENSOR PLUG - Ford Motor Co. part number F81Z-7H183-AA, and 2 are required, as shown in Figure 75. (6) LUBE ORIFICE PLUG - Ford Motor Co. part number F81Z-7E380-AA, which should come with the new case from Ford, as shown in Figure 76. (7) EXTENSION HOUSING - A 4R100 style with boss in the extension housing to retain the lube plug in the new design case, as shown in Figure 76. Continued on next Page Copyright © 2005 ATSG 82 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PARTS AFFECTED (Cont'd): REQUIREMENTS FOR 1989 THRU 1995 MODELS ONLY: (1) SPACER PLATE - Ford Motor Co. part number F81Z-7A008-EA or F8UZ-7A008-CA, as shown in Figure 72. (2) CASE TO SPACER PLATE GASKET - Ford Motor Co. part number F81Z-7C155-AA, with "White" stripe for identification, as shown in Figure 73. (3) SPACER PLATE TO V.B. GASKET - Ford Motor Co. part number F81Z-7D100-AB, with "Blue" stripe for identification, as shown in Figure 73. (4) COOLER BYPASS ASSEMBLY - Ford Motor Co. part number F81Z-7H322-AA, as shown in Figure 74. (5) SPEED SENSOR PLUG - Ford Motor Co. part number F81Z-7H183-AA, and 2 are required, as shown in Figure 75. (6) LUBE ORIFICE PLUG - Ford Motor Co. part number F81Z-7E380-AA, which should come with the new case from Ford, as shown in Figure 76. (7) EXTENSION HOUSING - A 4R100 style with boss in the extension housing to retain the lube plug in the new design case, as shown in Figure 76. (8) MAIN VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast into the valve body, in location shown in Figure 77, and checkball locations are shown in Figure 78. (9) LOWER VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast into the lower valve body, in location shown in Figure 77. (10) LOWER VALVE BODY SPACER PLATE - The 1996 hydraulics version which is identified by the 2 holes for bathtub checkball and 3 small holes, as shown in Figure 77. (11) ACCUMULATOR VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast into the accumulator valve body and slot cast shut, as shown in Figure 77. (12) CASE CHECKBALL LOCATIONS - Requires the 1996 and later case checkball locations, which is eight checkballs in locations shown in Figure 79. INTERCHANGEABILITY: Parts that have been mis-matched, depending on what you have done, can create; Harsh Shifts No Overdrive Bind in Manual 1 Lack of Lube Bind in Reverse Slip in Reverse SERVICE INFORMATION: Main Valve Body Spacer Plate .................. ...................................................... F81Z-7A008-EA Main Valve Body Spacer Plate (Optional) ....................................................... F8UZ-7A008-CA Case To Spacer Plate Gasket (White Stripe) .................................................... F81Z-7C155-AA Spacer Plate To Valve Body Gasket (Blue Stripe) ............................................ F81Z-7D100-AB Cooler Bypass Assembly .................................................................................. F81Z-7H322-AA Speed Sensor Plugs (2 Required) ...................................................................... F81Z-7H183-AA Lube Orifice Plug (Comes with new case) ........................................................ F81Z-7E380-AA Copyright © 2005 ATSG AUTOMATIC TRANSMISSION SERVICE GROUP 83 Technical Service Information FORD 4R100 MODIFIED CASE FOR USE IN E4OD MODELS ADDED OIL DAM DAM REMOVED FORD 4R100 CASE FORD MODIFIED 4R100 CASE FOR E4OD REPLACE Copyright © 2005 ATSG Figure 71 84 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information F81P-EA F81P-DA "SPECIAL" MAIN SPACER PLATE REQUIRED FOR MODIFIED 4R100 CASE Use Part Number For Identification F81Z-7D008-EA Copyright © 2005 ATSG Figure 72 AUTOMATIC TRANSMISSION SERVICE GROUP 85 Technical Service Information CASE AND VALVE BODY GASKETS REQUIRED FOR MODIFIED 4R100 CASE Blue I.D. Stripe F81Z-7D100-AB White I.D. Stripe F81Z-7C155-AA Copyright © 2005 ATSG Figure 73 86 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "4R100" COOLER BYPASS VALVE ASSEMBLY TO COOLER SEALING WASHERS FROM COOLER SEALING WASHERS COOLER LINE FITTINGS OEM PART NUMBER F81Z-7H322-AA Copyright © 2005 ATSG Figure 74 SPEED SENSOR PLUG F81Z-7H183-AA (2 REQUIRED) Copyright © 2005 ATSG Figure 75 AUTOMATIC TRANSMISSION SERVICE GROUP 87 Technical Service Information TYPICAL 4 WHEEL DRIVE E4OD 4X4 WITHOUT LUBE PLUG With Shoulder FORD 4R100 6.8L AND 7.3L 2 WHEEL DRIVE ALL OTHER 2 WHEEL DRIVE APPLICATIONS No Shoulder E4OD WITHOUT LUBE PLUG With Shoulder Added Boss No Shoulder Must use extension housing with shoulder or boss, to retain the lube orifice plug in the new case LUBE ORIFICE PLUG FORD PART NUMBER F81Z-7E380-AA Copyright © 2005 ATSG Figure 76 88 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information VALVE BODY CASTINGS REQUIRED FOR MODIFIED 4R100 CASE REQUIRED LOWER VALVE BODY I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" MODEL REQUIRED LOWER VALVE BODY SPACER PLATE "Two" Holes Over The Bathtub THREE "SMALL" HOLES I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" MODEL Identification One "V" Notch REQUIRED MAIN VALVE BODY 6TP B RF-F092-A 7A I.D.-ROUGH FORGING NUMBER OF "RF-F6" WHICH INDICATES "96" MODEL REQUIRED ACCUMULATOR VALVE BODY Copyright © 2005 ATSG Figure 77 AUTOMATIC TRANSMISSION SERVICE GROUP 89 Technical Service Information VALVE BODY CHECKBALL LOCATIONS REQUIRED FOR MODIFIED 4R100 CASE VALVE BODY CHECKBALL LOCATIONS REQUIRES THREE 1/4" RUBBER BALLS, AND TWO 5/16" RUBBER BALLS ROUGH FORGING NUMBER LOCATION RFF6TP7A092-AB 5/16" DIAMETER CHECKBALL 5/16" DIAMETER CHECKBALL 1/4" DIAMETER CHECKBALLS Copyright © 2005 ATSG Figure 78 90 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4R100 "MODIFIED" CASE CHECKBALL LOCATIONS REQUIRES EIGHT (5/16") RUBBER BALLS CB-8 CB-7 BS-3 BS-1 CB-6 CB-1 INTERMEDIATE ACCUMULATOR REGULATOR CB-14 FILTER ASSEMBLY SHIFT 1 AIR BLEED CB-9 SHIFT 2 AIR BLEED 1/4" STEEL BALL EPC RELIEF BALL Filter Assembly ......... F1TZ-7H194-A EPC Spring ............... E9TZ-7D017-A SPRING GOES INTO THE CASE FIRST SPRING GOES INTO THE CASE FIRST (USED ALL MODELS) Copyright © 2005 ATSG Figure 79 AUTOMATIC TRANSMISSION SERVICE GROUP 91 Technical Service Information 4R100 CASE PASSAGE IDENTIFICATION Copyright © 2005 ATSG Figure 80 92 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information ACCUMULATOR BODY PASSAGE IDENTIFICATION Copyright © 2005 ATSG Figure 81 AUTOMATIC TRANSMISSION SERVICE GROUP 93 Technical Service Information "ON/OFF" TCC PUMP COVER PASSAGE IDENTIFICATION CONVERTER CLUTCH REGULATOR VALVE CONVERTER CLUTCH CONTROL VALVE MAIN REGULATOR VALVE LUBE (TO COOLER) FROM FILTER Copyright © 2005 ATSG Figure 82 94 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "PWM" TCC PUMP COVER PASSAGE IDENTIFICATION CONVERTER CLUTCH REGULATOR VALVE CONVERTER CLUTCH CONTROL VALVE MAIN REGULATOR VALVE LUBE (TO COOLER) FROM FILTER Copyright © 2005 ATSG Figure 83 AUTOMATIC TRANSMISSION SERVICE GROUP 95 Technical Service Information OIL PUMP BODY PASSAGE IDENTIFICATION Copyright © 2005 ATSG Figure 84 96 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information THE REAL SCOOP ON FORD'S 4R100 POWER TAKE OFF OPERATION BY: JIM DIAL TECHNICAL CONSULTANT FOR ATSG In the last two years we have discussed in bulletins and seminars about all of the changes the 4R100 had to go through to be able to drive a "Power Take Off" (PTO) unit. This article is the real scoop on how the whole system operates electronically and hydraulically. Dale England and I had an opportunity to check out a 1999 Ford F550 Super Duty truck equipped with a 7.3 "Powerstroke" diesel. This vehicle had just been fitted with a PTO, to drive a pump, to run a "bucket type lift" for T.V. cable repair. We thought that this would be a great time to clear up some questions that we were curious about. The first question that needed to be answered was, What does the Powertrain Control Module (PCM) do when the "PTO" is turned on? Before we could answer that question, we had to find out how 12 volts was supplied to terminal 66 at the PCM. This was something we covered in last years seminar. We discussed how the technician, that was installing the PTO, had to supply their own 12 volt power source to terminal 66 on diesel models or terminal 4 on gas models, to tell the PCM when the PTO mode was selected. We decided to check terminal 66 of the PCM where we found a Blue with a Yellow stripe wire that headed back in towards the cab. We followed the wire under the column area , as shown in Figure1, and found a tag that was taped to the wire that stated "PTO Enable." This wire is supplied by Ford, which is information we were not sure of before. The company that installed the PTO on this truck, had set up their own relay that was wired so there would be "no" voltage supplied to terminal 66 until the selector is in the Park position and the Parking brake is "on." This is an obvious safety precaution. It was now time to find out the shift solenoid strategy, now that terminal 66 was handled. We proceeded to hook up some test equipment to the solenoid pack to monitor the PCM signals and we placed the selector in Park and set the Parking brake. I started the vehicle and reached up and pushed the PTO button.........nothing happened. GREAT!......it worked before we touched it, famous last words! The first thing we thought was ......maybe we disturbed a connection along the way to terminal 66. We checked all of our conections and verified 12 volts at terminal 66, with the PTO button "on", and still nothing. After screwing around for half an hour we decided to swallow our pride and call the person that installed the PTO. He came to the phone and we told him about the problem and what we had done. The first thing out of his mouth was, "did anyone , by chance, disconnect the batteries for any reason?" My jaw hit the floor......when we checked terminal 66 at the PCM we had to disconnect the batteries so we could unplug the connector from the PCM safely. Long story short, the PCM must have a 7 mile drive cycle at speeds over 50 mph. before it remembers that it is capable of running a PTO! Well, needless to say, we felt like complete idiots! and yes, that fixed it. So....... now after wasting all of this time, we placed the selector in Park and set the Parking brake. When the PTO button was depressed the following things happened: •The PCM turned the no.2 solenoid "ON" •The OD Cancel Light came on and the Coast Clutch Solenoid was turned "ON" •The PCM brought engine rpm up to approximately 1500. (Powerstroke diesels are "Drive By Wire" as in they have NO throttle cable). •EPC pressure rose to about 55psi •When engine idle hit about 1500 rpm the TCC solenoid came on. All of this happened within a few seconds. In Figure 2 we have provided a partial hydraulic circuit diagram to show some of the hydraulic changes that had to be made to the 3-4 shift valve and why these changes were necessary. As you can se, the 3-4 shift valve is now connected to line pressure AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information REMOVE STEERING COLUMN COVER PTO ENABLE THE PTO ENABLE WIRE IS LOCATED IN THE WIRING LOOM UNDER THE STEERING COLUMN Copyright © 2005 ATSG Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information "PTO -ON" 3-4 SHIFT VALVE HYDRAULIC CIRCUIT FROM SOLENOID 4 / COAST CLUTCH SOLENOID "ON" FROM SOLENOID 2 "ON" TO CB3 / COAST CLUTCH LINE PRESSURE FROM PRESSURE REGULATOR VALVE COAST CLUTCH SHIFT VALVE 3-4 SHIFT VALVE TO CB7 / OVERDRIVE CLUTCH LEGEND MAIN LINE PRESSURE SOLENOID REG. VALVE OIL EXHAUST FROM 2-3 SHIFT VALVE X X Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP Copyright © 2005 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 221 .040" 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 250 SRV 241 352 REVERSE 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 240 LUBE BS3 .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 CB6 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE OD123/R 540 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR EXH. 377 CB16 CB13 543 378 511 510 .059" 375 REVERSE 356 512 .100" 527 .040" LINE 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE SOLENOID 2 AIR BLEED 86 X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" S1 159 LINE PRESSURE TAP CB9 426 SRV RANGE "PARK" 417 EPC BLOW-OFF S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "ON" "OFF" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 221 .040" 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 250 SRV 241 352 REVERSE BS3 240 LUBE .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 CB6 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE 540 OD123/R 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR EXH. 377 CB16 CB13 543 378 511 510 .059" 375 REVERSE 356 512 .100" 527 .040" LINE 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE SOLENOID 2 AIR BLEED 86 X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 426 SRV 417 CB9 .051" LINE PRESSURE TAP S1 159 EPC BLOW-OFF RANGE "REVERSE" S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "ON" "ON" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE DIRECT CLUTCH FORWARD CLUTCH OVERDRIVE CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 221 .040" 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 250 SRV 241 352 REVERSE BS3 240 LUBE .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 CB6 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE OD123/R 540 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR EXH. 377 CB16 CB13 543 378 511 510 .059" 375 REVERSE 356 512 .100" 527 .040" LINE 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" LINE PRESSURE TAP CB9 426 SRV S1 159 EPC BLOW-OFF 417 RANGE "OVERDRIVE" 1st GEAR SOLENOID 2 AIR BLEED 86 S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "ON" "OFF" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE DIRECT CLUTCH FORWARD CLUTCH OVERDRIVE CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 221 .040" 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 250 SRV 241 352 REVERSE BS3 240 LUBE .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 CB6 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE OD123/R 540 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 EXH. 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR CB13 543 377 CB16 512 .100" 527 .040" 378 511 510 .059" 375 REVERSE 356 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" LINE 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" LINE PRESSURE TAP CB9 426 SRV S1 159 EPC BLOW-OFF 417 RANGE "OVERDRIVE" 2nd GEAR SOLENOID 2 AIR BLEED 86 S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "ON" "ON" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH OVERDRIVE CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 221 .040" 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 250 SRV 241 352 REVERSE BS3 240 LUBE .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 CB6 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE OD123/R 540 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 EXH. 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR CB13 543 377 CB16 512 .100" 527 .040" 378 511 510 .059" 375 REVERSE 356 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" LINE 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" LINE PRESSURE TAP CB9 426 SRV S1 159 EPC BLOW-OFF 417 RANGE "OVERDRIVE" 3rd GEAR SOLENOID 2 AIR BLEED 86 S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "OFF" "ON" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH OVERDRIVE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 221 .040" 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 250 SRV 241 352 REVERSE BS3 240 LUBE .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 CB6 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" 223 CB14 355 353 1 CL B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE 540 OD123/R 545 OD123/R 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 EXH. 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR CB13 543 377 CB16 512 .100" 527 .040" 378 511 510 .059" 375 REVERSE 356 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" LINE 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE SOLENOID 2 AIR BLEED 86 X X 1-2 MANUAL TRANSITION VALVE 85 LINE PRESSURE TAP 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 CB9 426 SRV 417 S1 159 EPC BLOW-OFF .051" RANGE "OVERDRIVE" 4th GEAR S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "OFF" "OFF" "OFF" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH OVERDRIVE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 262 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 221 .040" 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 250 SRV 241 352 REVERSE 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 240 LUBE BS3 .031" CONVERTER REGULATOR VALVE S4/1-R/M2 DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 CB6 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" CB14 355 353 1 CL 223 B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE 540 OD123/R OD123/R 545 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 EXH. 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR 543 377 CB16 CB13 512 .100" 527 .040" 378 511 510 .059" 375 REVERSE 356 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" LINE 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" LINE PRESSURE TAP CB9 426 SRV S1 159 EPC BLOW-OFF 417 RANGE "OVERDRIVE" 4th GEAR TCC ON SOLENOID 2 AIR BLEED 86 S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "ON" "OFF" "OFF" "OFF" *=passage in the gasket to orifice Copyright © 2000 ATSG LUBE CENTRAL LUBE REAR LUBE FORWARD CLUTCH DIRECT CLUTCH OVERDRIVE CLUTCH INTERMEDIATE CLUTCH LOW/REVERSE CLUTCH FORWARD CLUTCH DIRECT CLUTCH INTERMEDIATE CLUTCH OVERDRIVE CLUTCH "NON-PWM" PUMP REAR VIEW S4/1-R/M2 COAST CL. 268 CB8 230 349 TO FRONT LUBE 1-R 261 REVERSE 261 P R N D 2 1 .079" 222 368 MANUAL VALVE SOLENOID REG. VALVE 321 .070" 285 LINE 262 OD OD .060" 289 * 258 275 242 243 1-R 224 .040" 255 270 .059" 272 221 .040" 251 LINE 267 348 364 341 .030" 244 S4 365 CONVERTER CLUTCH CONTROL VALVE 250 SRV 241 352 REVERSE 374 REVERSE MAIN REGULATOR VALVE BS1 1-R/M2 240 LUBE BS3 .031" DIRECT CLUTCH ACCUMULATOR LUBE OVERDRIVE CLUTCH ACCUMULATOR CONVERTER REGULATOR VALVE 369 M123/R 269 226 .060" 351 PRN1/X 259 287 L/R CL. 342 .100" 343 366 OD34/R 376 .049" 320 .046" .090" .030" CB7 371 OD.CL. 347 L.MOD. 346 L.MOD. LOW/REVERSE MOD. VALVE 232 CB6 291 LINE SRV 288 REVERSE 252 281 S2 367 R/1-R 332 322 EPC COAST CLUTCH SHIFT VALVE 225 277 LINE 231 CB1 350 REVERSE 370 REVERSE 256 4-3-2 MANUAL TIMING VALVE 358 OD4 TCC SOLENOID SIGNAL 3-4 SHIFT VALVE 253 PRN1/X 278 REVERSE 271 OD234 354 TO SUMP 319 .100" COAST CLUTCH .087" CB14 355 353 1 CL 223 B12 280 S1 234 .090" 279 S1 257 282 F CL. 254 284 PRN1/M2 283 373 1 CL EPC 325 .046" 519 .059" .093" 557 REVERSE 559 .059" 558 CB15 556 562 REVERSE 553 OD34/R 552 EXHAUST 561 EXHAUST 564 REVERSE 540 OD123/R OD123/R 545 534 S2 541 M2/S2 551 550 549 OD34/R M2 548 BS2 538 537 REVERSE 546 PRN1 539 M2/S2/X LINE MODULATOR VALVE 544 PRN1 INTERMEDIATE CLUTCH ACCUMULATOR EXH. 377 CB16 CB13 543 378 511 510 .059" 375 REVERSE 356 512 .100" 527 .040" LINE 2-3 SHIFT VALVE 1-2 & D2 SHIFT VALVE 513 357 .063" 526 FORWARD CLUTCH 324 TO COAST CLUTCH LEGEND LINE PRESSURE EPC PRESSURE ENGAGEMENT CONTROL VALVE LINE MOD PRESSURE SRV PRESSURE X X 1-2 MANUAL TRANSITION VALVE 85 431 435 EPC 443 LINE 434 LINE 441 LINE 429 EPC 432 SRV 419 S4 436 S4 422 S4 160 433 SRV 420 S2 158 INTERMEDIATE SERVO 428 430 416 .051" LINE PRESSURE TAP CB9 426 SRV S1 159 EPC BLOW-OFF 417 RANGE "PARK" PTO ON SOLENOID 2 AIR BLEED 86 S3 CONV. DISCHARGE PRESSURE SOLENOID 1 AIR BLEED SRV LUBE CONV. REGULATED PRESSURE X 427 EXHAUST 4R100 "PTO" VERSION "NON-PWM" 418 PRIMING L/R PRESSURE INTERMEDIATE SERVO (M2) EPC TCC SS1 SS2 CCS "ON" "ON" "ON" "ON" *=passage in the gasket to orifice Copyright © 2000 ATSG