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Service Information Highlights
Reference Book and Tech News
8-Speed Automatic Transmission Update and Service Best Practices
REFERENCE BOOK AND TECH NEWS November 2012
Reference Book and Tech News
Service Information Update
INTRODUCTION This month, we have two Master Tech programs. The first program will focus on the three different 8-speed transmissions offered in Chrysler Group vehicles: the 8HP45, the 845RE, and the 8HP70 (Fig. 1). We’ll give a brief overview of the 8HP45 before we talk about some of the things you can look forward to in the near future.
Figure 1: 8HP45 (left), 8HP70 (middle), 845RE (right) We’ll give a brief overview of the 8HP45 before we talk about some of the things you can look forward to in the near future. We’ll then turn our attention to the 845RE. After discussing what vehicles you’ll find the 845RE in, we’ll get into some of the internal components and discuss some of the service implications, focusing on how it differs from the 8HP45 and 845RE. Then we’re going to spend time looking at the service procedures that are unique and noteworthy.
Figure 2: 8HP70 Transmission
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After going over the three 8-speed transmissions in detail, we’ll turn our attention to the new for 2013 Ram 1500 Stop/Start system. We’ll explore the components that are unique to the Stop/Start system first, and then we’ll take a look at the enablers that make the system work. Naturally, we’ll discuss the service points you’ll need to know in order to keep this system up and running properly. Lastly, we’ll cover some of the diagnostic information you’ll need to service the Stop/Start system. After that we'll have a short bonus program: Service Best Practices. In that program, we'll look at some recommendations and new technology that will affect the entire service department. Note that the Master Tech Reference Book contains information not found in this month's web program. However, you will need the web program to answer the questions in the online quiz. This month's Tech News continues with a Tech's Corner article. It's a good practice to review the reference book as you progress through the web course.
Table of Contents: INTRODUCTION ..................................... 2 8-SPEED TRANSMISSION OVERVIEW ................ 4 8-SPEED TRANSMISSION SERVICE .................... 6 FUEL EFFICIENCY IMPROVEMENTS .................................. 10 RAM STOP/START ............................... 12 REPAIR ORDER PATH ......................... 14 WIADVISOR ............................................ 15 THREE Cs AND SIX STEPS ................. 18 VEHICLE NOT REPAIRED WORKSHEET ......................................... 19 TECH’S CORNER ................................... 21
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8SPEED TRANSMISSION OVERVIEW The 8HP45 was covered in-depth in the June 2011 Master Tech program. If you missed that one, you’ll want to go back and review the program. Here is a quick overview. The 8HP45 is built by ZF in Germany. It arrives in the U.S. and is installed as an assembly. This transmission was launched in the 2012 model year in the Dodge Charger and Chrysler 300. For the 2013 model year you’ll also find the 8HP45 in the Ram 1500.
In mid-2013, the Ram 1500 will switch from the ZF-built 8HP45 to the Chryslerbuilt 845RE, still paired only with the 3.6L V-6. The 8HP45 and 845RE transmissions look nearly identical from the outside. It’s only when you get inside the case that things start to look different (Fig. 4).
Vehicles with the Stop/Start feature have technologies that set them apart from vehicles without the Stop/Start system. (Fig. 3). Figure 4: 8HP45 and 845RE internal components
Figure 3: Unique Components of the Stop/Start System It should also be noted that the 8HP45 only comes behind the 3.6L engine. The 845RE is based on the ZF-designed 8HP45, but it is built by Chrysler in Kokomo, Indiana. In 2012, expect to see this technology being used in more Chrysler Group vehicles, including the Jeep Grand Cherokee, Dodge Durango, and more.
While some internal components will share part numbers, most internal components will not be interchangeable between the 8HP45 and the 845RE. For instance, while the clutch packs look very similar, they are not interchangeable. Looking a little closer at the 845RE clutch packs, the D clutch has an extra pair of separator and friction plates for improved vehicle performance (Fig. 5).
Figure 5: Extra Clutch and Separator in the D Clutch
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You’ll also notice a deeper oil pan on the 845RE used in the Grand Cherokee. This gives not only increased fluid capacity, but also improves lubrication (despite the angle of installation) (Fig. 6).
Figure 6: 8HP45 Oil Pan on Bottom, 845RE Oil Pan on Top The ZF-built transmissions can only be serviced to a certain extent while under warranty. Refer to warranty bulletin D12-21 for more information. The 8HP70 8-speed automatic transmission is built by ZF in Germany and received as an assembly. This new transmission will roll out in the 2013 calendar year in the Ram 1500, Jeep Grand Cherokee, and the Dodge Durango.
While a few parts are interchangeable, most are not. The 8HP70 is a larger, heavier-duty version of the 8HP45. Due to the increased size, you’ll find the majority of the internal components such as rotating components, the case, and output shafts (among others), are not interchangeable. The majority of the service tools, as well as diagnostics, are common between the 8HP45 and the 8HP70.
The 8HP70 looks similar to the 8HP45, being almost the same length, even having similar components (Fig. 7).
Figure 7: 8HP70 Rear, 8HP45 Front
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8SPEED TRANSMISSION SERVICE The first procedure we’ll cover is the manual park release. There are two different procedures: one for cars, and one for the Ram truck. The Ram 1500 has the release behind this trim panel, above the parking brake release handle. To manually release the park lock, push this lock aside before pulling on the red strap (Fig. 8). The lever will latch into the unlock position, putting the transmission in neutral.
Figure 9: Release This Clip Before Pulling the Park Release Lever The lever is held upright by another clip. This clip must be released before the lever is pushed back down to engage park (Fig. 10).
Figure 8: Slide the Lock to Release the Park Release Lever After sliding the lock to the side again, the lever will snap back into place, putting the transmission back in park. The procedure is a bit different on the Charger and the 300. After removing the trim piece, you’ll find the release lever; don’t pull it just yet. You have to release this clip before pulling the strap. (Fig. 9). If the clip is not released it will break, causing the lever to rattle.
Figure 10: Release This Clip Before Releasing Lever Only ZF 8- and 9-speed ATF can be used in the 8-speed transmission. A note about fluid leak diagnosis: No transmission fluid additives, including leak detection dye, can be used in the 8HP family transmissions. With that in mind, the transmission fluid used in the 8-speed family glows under UV light already. Keep this in mind when looking for other types of fluid leaks as you could get a false positive if transmission fluid is in the area.
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Speaking of fluid, the fluid check and fill procedures were covered in depth in our June 2011 release for the 8HP45. It is the same procedure for the 845RE and 8HP70 with the exception of fluid volumes.
When disassembling the transmission, it’s important to note that the gear train needs to be removed vertically. The drums are aluminum and are easily damaged (Fig. 12).
The procedure for checking and filling the fluid on an AWD Chrysler 300 or Dodge Charger is a bit different. First, you’ll need to remove the front propeller shaft to gain access to the plug. Next, use wiTECH to put the vehicle into Emissions Rolls Test Mode while engaging the necessary gears (Fig. 11). Figure 12: The Gear Train Must Be Removed Vertically To avoid damaging the aluminum D clutch drum and the P4 annulus drum, use special tool number 10378 (Fig. 13).
Figure 11: Use the Emissions Rolls Test While Checking Transmission Oil Then you can pull the plug to check the level or top it off as needed. When you are done, install the front propeller shaft and be sure to manually disable the test mode to avoid setting trouble codes. If the transmission needs to be removed from the vehicle for service, be aware that the transmission oil pan is made of a composite material, not stamped steel. Be sure the weight of the transmission is evenly supported on the lifting fixture or damage to the transmission will occur. Before opening the transmission, it is important to note that a clean work area is critical due to the very tight tolerances in these transmissions.
Figure 13: Special Tool Number 10378 Please note that the P1 carrier and P2 annulus snap rings are one-time use snap rings. During installation, use a flatblade screwdriver to coax the snap rings into the groove in the drum. Next, we will go over how to set up the B clutch. This segment is meant to give you an overview of the procedure, refer to service information for the complete procedure.
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The first measurement we need is the depth of the bore in the housing where the B clutch sits (Fig. 14). This dimension represents the total area filled by the B piston and clutch pack.
Figure 14: The Bore Where the B Piston and Clutch Sit The second measurement is the height of the clutch pack after it has been compressed. The pressure against strain gauge special tool number 10429 must match the specification given in the service information (Fig. 15). We are using portions of special tool number 8901A that was designed for the NAG1 transmission.
Figure 15: Clutch Pack Height Is Measured After Being Compressed
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The final measurement we need is the height from the B clutch piston to the oil pump housing mating surface (Fig. 16).
Figure 16: B Clutch Piston to Oil Pump Housing Mating Surface Measurement Subtract the B piston measurement and the clutch height measurement from the bore depth and you have your end clearance measurement. We are looking for a clutch pack end clearance between 1.26 mm and 1.67 mm. To adjust the clutch pack clearance within specifications, the flange plate is available in different thicknesses. Select the appropriate size. After replacing the flange plate, take the measurements again. Besides the snap rings mentioned earlier, the oil pump bolts, the pump housing bolts, as well as the valve body bolts are one-time use. Refer to service information for more detail. A note about gear train end play: Because the oil pump housing bolts are one-time use bolts, it is a good idea to use the old bolts while adjusting the end play. After the correct end play has been established, use new bolts for the final installation of the oil pump housing.
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FUEL EFFICIENCY IMPROVEMENTS There are two unique features introduced with the 2013 Ram truck that we’ll get into now. Introduced with the 2013 Ram trucks is a thermal management unit (TMU) (Fig. 17).
Figure 17: Thermal Management Unit The 8HP transmission family is such an efficient transmission there is a need for an auxiliary heater to keep the transmission oil at the proper temperature, about 80°C (176°F). Engine coolant is carried back to a heat exchanger via coolant pipes. In this illustration, the hoses and pipes have been color-coded to show the hot and cold portions of the system (Fig. 18). The coolant pipes and heat exchanger are serviceable separately.
Figure 18: Coolant Pipes Are Part of the TMU System
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The second unique feature we’ll cover is the hydraulic impulse storage (HIS) unit (Fig. 19). The HIS is a spring-loaded accumulator with a latching solenoid that is part of the Stop/Start feature.
When the engine is running, transmission oil is pumped into the HIS accumulator and is stored. A locking solenoid keeps the piston under tension until the piston is released. Spring pressure takes over and the piston pushes the fluid out of the HIS and into the transmission. As soon as the engine is restarted, the HIS is filled with fluid and ready for the next cycle.
Figure 19: HIS Unit
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RAM STOP/START New for the 2013 Ram 1500 is a Stop/Start feature that turns off the engine when the vehicle comes to rest, restarting it automatically when needed. You’ll find a graphic in the reference book that shows the different components in the Stop/Start system. We’ll cover some of them now. The powertrain control module (PCM) calibration dictates when the engine will shut down and restart. This decision is based on brake pedal position, vehicle speed, and time stopped, among others.
All Stop/Start equipped vehicles have an absorbed glass mat (AGM) battery and heavy-gauge cables, that are able to deliver higher amp loads consistently. Naturally, the alternator needs to be heavy-duty as well. This one is a 220-amp alternator that provides greater charging capacity immediately after auto-starts. Inside the transmission, we have the HIS (Fig. 21). The HIS enables the transmission to build full line pressure, allowing a nearly instantaneous response to the driver's input.
The DC-to-DC converter takes battery voltage and steps it up to a higher voltage to keep electrical features like the fan, wipers, headlights, and audio system going until the engine restarts (Fig. 20). Figure 21: HIS Cutaway View This completes our program on the 8speed transmissions. The November Master Tech bonus program follows.
Figure 20: DC-to-DC Converter Naturally, a system like this places a considerable load on the starting and charging systems. The starter motor is a heavy-duty, brushless design, better able to cope with the demand placed on it.
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Stop/Start Components
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REPAIR ORDER PATH How many times have you been given a repair order to resolve a customer’s concern only to be unable to duplicate the problem? This month we have a bonus program: Service Best Practices. The first thing we’ll do is follow a repair order through the service department from the first contact with the customer, through the technician, and on to the point that the customer picks up the vehicle. As part of this Service Best Practices program, we’ll cover the new Service Advisor Dashboard system. This new repair order initiation system will streamline the write-up and repair processes. After exploring the Service Advisor Dashboard system, we’ll cover the two most basic and important aspects of the repair process; the Six-step Troubleshooting Procedure and the three Cs. The last topic in this bonus program covers the Vehicle Not Repaired Check Sheet. This check sheet helps to guide you through the inspection process so you can document everything and make sure all angles are covered. As part of our November Service Best Practices program, let’s review the life of a repair order. This helps us to better understand the processes that will be discussed shortly.
It all begins with the customer expressing a concern to a service advisor who records it for the technician. Naturally, the more detail that is recorded the better. Currently, there are a few different ways this write-up process is handled, but a new consistent process is in development. The next lesson will cover that new system. After the write-up process, the repair order is dispatched to the technician. This can be handled in a few different ways as well, depending on the dealership. Looking over a repair order when it is first assigned is the best way to review the customer concern and ask questions about the concerns listed. In fact, the customer may still be there to answer first hand. At this point in the process, the first C (the Concern) is in place. We’ll go into more details related to the three C’s shortly. Now it’s time to fix a car. During the diagnostic and repair phase, it’s recommended to follow the Six-step Troubleshooting Procedure and document this on the repair order. After the concern is corrected, the completed repair order is returned to the dispatcher or manager. From here, the repair order goes through various processes that may include Warranty Reimbursement. We will finish our program with some helpful hints when submitting warranty claims for Trouble Not Found concerns.
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WIADVISOR In an effort to simplify the service write-up process and improve our customer satisfaction, Chrysler Group has developed a new tool for service advisors called wiADVISOR (Fig. 22). The wiADVISOR program will extend the wiTECH network that is currently installed in your shop into the service drive. What’s the advantage of this new system?
Figure 22: wiADVISOR Welcome Screen Currently, on average there are 15 different steps performed from the time the customer schedules an appointment to when they sign the repair order. This doesn’t include things like following up with the customer, checking parts-ordered status, talking to the technician, and so on.
wiADVISOR will soon be adding a feature to assist the service advisor in accurately capturing the customer's concern by asking questions based on the type of issue. The answers to these questions will be included on the repair order to assist in diagnosis. The system also allows for the service advisor to add comments to the repair order.
The need for a more efficient, consistent, and accurate write-up system is being answered. wiADVISOR answers these concerns by improving every step of the write-up process. Keep in mind that the screens you will be shown are prototype screens, they may differ from what you'll see in the future. Let’s look at how this system works and how it affects technicians.
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The wiADVISOR system includes a wiTECH microPod that plugs into the OBDII port (Fig. 23).
Figure 23: microPod An access point extends the dealership’s dedicated service network into the service drive, enabling the microPod to communicate (Fig. 24).
Figure 25: microPod Plugs into the OBDII Port If the customer has taken advantage of the online service scheduling capabilities, much of this information will be populated before the customer drives through the door. The next step is to document the customer’s concerns. The service advisor will interview the customer as before, but the wiADVISOR program utilizes a series of drop-down menus to walk the advisor through the process (Fig. 26).
Figure 24: Wireless Access Point For up-to-date information on recommended tablets, please access the wiADVISOR Knowledge Base by logging into the wiTECH Portal at: http://portal.dcctools.com.
Figure 26: Customer Concern Window
In practice, the customer is greeted by the service advisor, who plugs the microPod into the OBDII port (Fig. 25). wiADVISOR pulls vehicle information (such as VIN and odometer readings) from the various computer systems in the vehicle, key information from the VIP report and other Chrysler Group databases (such as customer information), and information from the dealer management system.
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Besides the consistent write-up process, there are other advantages that the service advisor, as well as the technician will notice. Some of these are:
The ability for the customer to schedule appointments electronically
A VIN- and odometer-specific maintenance menu to show customers exactly what their vehicle maintenance requirements are at that visit.
A function called Vehicle Systems Vitals identifies any outstanding recalls, Rapid Response Transmittals, and available flash updates
Up-to-date service history at the tap of a screen
An optional subscription to features like the Electronic Vehicle Inspection Module, which provides technicians with the ability to perform inspections electronically
A running estimate of repair costs
The wiADVISOR roll-out process has already begun. If your dealership isn’t using it yet, you’ll see it soon.
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THREE Cs AND SIX STEPS From the technician’s perspective, there are few things that affect your day more than the three Cs and the Six-step Troubleshooting Procedure. The six steps ensure a proper and complete repair while the three Cs make sure everything is documented. We’re going to lump these together because they are completed at the same time. The first C (the Concern) is documented by the service advisor (Fig. 27). This information is the most important piece of information you will use when repairing the vehicle.
The third step is to analyze the symptoms. Are the symptoms related, or did you discover something the customer should be made aware of? The fourth step is to isolate the cause. Use published service information to determine the cause of the concern. This is where the second of the three Cs comes in (the Cause). Write detailed notes of the cause of the concern on the repair order. This will aid not only your warranty administrator when the claim is being prepared but also will provide important details to Chrysler to help in improving the quality of our products. The fifth step is to repair the concern. Now it’s time for the third C (the Correction). You don’t have to write a novel here, but you do have to make sure you document clearly what was done to correct the concern for the customer.
Figure 27: Concern Is Documented During Write-up Your job starts with the first of the six steps, verify the concern. Always review all of the information on the repair order so you are reproducing this concern under the same conditions that the customer reported.
The final step in the Six-step Troubleshooting Procedure is to verify vehicle operation. This is where you circle back to the first step and try to reproduce the concern under the same conditions the customer described.
Step two is to determine any related symptoms. Maybe the clunking noise they are concerned about is related to the uneven tire wear they didn’t notice.
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VEHICLE NOT REPAIRED CHECK SHEET Sometimes technicians will simply not be able to address a customer’s concern, no matter how hard they may try. Many times, the technician will simply write TNF or something similar on the repair order and move on to the next job as quickly as possible. This usually ends up with a frustrated customer and technician, and we all know these vehicles come back at some point in the near future anyway. In the event that you were not able to duplicate a concern for any reason, it’s a good idea to fill out the Vehicle Not Repaired Check Sheet. Let’s look at the high points now. To access the check sheet, from the Service tab in TechCONNECT scroll down to the Repair Information section. From there, open the Other menu and open the Vehicle Not Repaired Check Sheet (Fig. 28).
The first portion in this section is for documenting situations like this. There are situations when the concern cannot be duplicated. That’s what the second portion is for. It allows you to document that you checked the system(s) in question, checked for trouble codes, Service Bulletins, Recalls, or rapid response transmittals. You’ll also find a place to document a call to the STAR center, or to document if other dealership personnel road tested the vehicle. The third portion in this section is for situations where the part is not available to repair the car. Fill out the appropriate field to document the issue. The final section of the check sheet is to document the final outcome. Record the mileage in and mileage out whether or not the customer has been advised of the situation, and the conclusion of the repair order. Attach this check sheet to the repair order. It only takes a few minutes to complete this check sheet but it can really pay off in the end because everything is documented.
Figure 28: Vehicle Not Repaired Check Sheet Location The top portion is pretty self-explanatory, but be sure to copy, word-for-word, the customer’s concern onto the check sheet. The next section of the sheet has three reasons why the vehicle was not repaired; we’ll go over each of the three now. In some cases there really isn’t a problem with the vehicle, just a lack of understanding on the owner’s part.
Chrysler allows dealers to submit warranty claims for Trouble Not Found (TNF) diagnosis. All time allowance reimbursed is for Actual Time only. It is imperative to properly document any claim that requests reimbursement. The check sheet will allow the Warranty Administrator the ability to ensure that the claim is properly documented so that if authorization is required, individuals reviewing the claim can logically make the decision regarding reimbursement.
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The check sheet will allow the Warranty Administrator the ability to ensure that the claim is properly documented so that if authorization is required, individuals reviewing the claim can logically make the decision regarding reimbursement. In the near future, we will be providing additional details regarding Warranty Claim requirements. Additional information can be located in the Warranty Administration Manual available on DealerCONNECT. That completes the November Master Tech bonus program. Be sure to see this month’s web program for additional information about this month’s topics. Also, visit the Chrysler Academy Learning Center site for training courses that cover subjects related to these topics. Please join us next month when the topic is 2013.5 Diesel Powertrain Update. Thank you for participating in the Master Tech program.
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TECH’S CORNER In our Master Tech program for October, Mopar Accessories and Performance Parts, we reviewed some of the new accessories available on Chrysler products such as the rear center tail light assembly with the race track graphic available on the 2013 Dodge Dart, the Mopar signal mirror kit, and the new digital brake trailer controller available on the Dodge Durango and Jeep Grand Cherokee. In reviewing your surveys for the October, it appears that the program was well received with one technician telling us that it contained “very interesting info on new products and installation.” Another tech felt that addressing accessories and modifications to Chrysler vehicles shows the customer’s desire to customize and upgrade a vehicle’s capacity. We agree, and due to the popularity of these accessories, in addition to offering a Master Tech program on Mopar in October 2011, we decided to produce another one this October.
As you know, we also included a segment in the October program on the new Mopar JK-8 conversion kit for the Jeep Wrangler Unlimited. Some of you said that you enjoyed learning about the JK-8 conversion and tips related to the process. Others felt that JK-8 pertains more to body shop techs than to service technicians. Another tech’s response indicated that there was too much on installation of accessories, but went on to say that the JK-8 installation info was just right. So, as you can see, we do review your surveys. In fact, we also use them to come up with future Tech News topics, which allow us to answer your specific concerns. So, please continue to send in your ideas and suggestions.
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Can you guess the cars below? You can put your answers in your surveys.
1)
2)
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The answer to the October puzzle:
Across 3. To connect the passenger side of the Mopar signal mirror’s body harness, locate the ____ section of the harness containing two terminals. 5. Installation of an exhaust system that eliminates the converter will result in a ____ indicator lamp for a catalyst efficiency error.
Down 1. When installing exhaust system components it’s important to not ____ the clamps until all of the parts are installed. 2. When installing the Mopar signal mirror assembly, to populate the door jamb connector, how many terminals must be inserted into the door side of the connector?
7. What kind of a graphic is created by the LED lights in the 2013 Dodge Dart’s rear center tail light assembly?
4. The new 2012 Jeep Wrangler with a 3.6-liter engine uses a specially shaped pipe in the ____.
10. The Mopar signal mirror kit’s body harness is designed to connect both sides of the vehicle with a ____ that will reach up to the body control module. 12. When installing the Mopar JK-8 conversion kit components what type of drill should be used? 13. When removing panels during the JK-8 installation process do not drill through the ____ panel. 14. In 2012, the Ram 1500 received a redesigned ____ axle assembly. 16. All of the current Mopar cold air intake kits come with ____ exemption stickers.
6. When installing the Mopar JK-8 conversion kit, follow all Chrysler recommended ____ inhibiting procedures.
8. To connect the driver side of the Mopar signal mirror’s body harness, locate the ____ section of the harness containing two terminals. 9. When running the Mopar signal mirror’s new body harness along the existing harness, it should not interfere with the ____ shaft. 11. The new Mopar rear center tail light assembly features ___ lights. 15. How many harnesses are included in the Mopar signal mirror kit?
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