Jf506e 2
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Jatco 5 Speed
1
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
3
T ab able le Of C ont ent s Transmission Diassembly Diassembly ........ .................. ................... ................... ................... .................. ................... ................... ........... .. 4 Front Pump ......... .................. ................... ................... ................... ................... .................. ................... ................... .................. ............. .... 16 Reverse/High Clutch Drum ......... .................. ................... ................... .................. ................... ................... ................. ........ 18 Direct Clutch Drum .......... ................... ................... ................... ................... ................... ................... ................... .................. ......... 22 Low Clutch Drum ......... .................. ................... ................... ................... ................... .................. ................... ................... ............. .... 26 Planetary Gearsets Gearsets ......... .................. ................... ................... .................. ................... ................... .................. ................... ............ .. 29 Transfer Gear/Reduction Gear/Reduction Gear......... Gear .................. ................... ................... .................. ................... ................... ............. .... 30 Rear Cover Cover......... .................. ................... ................... ................... ................... ................... ................... ................... ................... .............. ..... 33 Valve Body ......... .................. ................... ................... .................. ................... ................... .................. ................... ................... .............. ..... 35 Transmission Case Case Assembly ........ .................. ................... ................... ................... ................... ................... ............... ...... 44 Bearing Race Location .......... ................... .................. ................... ................... .................. ................... ................... ............... ...... 64
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
Tr ansmi ss i on Case: Case: Di sas se semb mbly ly 1.
Remove the side cover.
2.
Remove the bol Remove boltt hold holding ing the in inter ternal nal har harnes ness s conn connect ectors ors an and d disc disconn onnect ect the (2) internal harness connectors.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 3.
5
Remove Remo ve onl only y the the val valve ve bod body y bolt bolts s show shown n and and rem remov ove e the the valv valve e body body.. To To get get to the bolt under the wiring (arrow) disconnect the solenoid.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
4.
Remove Remo ve the the cas case e conn connec ecto torr reta retain inin ing g clip clip and and rem remov ove e the the inte intern rnal al wir wirin ing g harness.
5.
Remove th the va valve bo body to to ca case se seals
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 6. 7.
Remov Rem ove e th the (22 (22)) bel belllho hous usiing to to ca case bol oltts. Ligh Li ghtl tly y tap tap the the conv conver erte terr hous housin ing g with with a pl plas asti tic c hamm hammer er to to sepe sepera rate te the the halves.
8.
Remove th the di differential.
9.
Remo Re move ve th the e fil filte ter, r, pu pump mp OO-ri ring ng an and d the the in inpu putt sha shaft ft OO-ri ring ng..
10. 10. 11.. 11
Remove Remo ve the the fro front nt pum pump p and and the the ga gask sket et.. Rem Re mov ove e th the e in inpu putt sh shaf aft. t.
7
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
12. 12. 13.. 13
Remove Remo ve the the red reduc ucti tion on gea gearr asse assemb mbly ly.. Remo Re move ve th the e red reduc ucti tion on su sun n gea gearr ass assem embl bly. y.
14. 14. 15... 15.
Rem emo ove the di dire rect ct cl clu utc tch h. Remove Rem ove the the reduc reductio tion n brake brake band band and and the band band ancho anchorr bolt. bolt.
16.
Remove Rem ove the the (16) (16) rear rear case case cov cover er bolts bolts.. Note Note the the O-ring O-rings s on the the two two larg larger er bolts.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
9
17. 18.
Remove the 2-4 pis Remove piston ton an and d the the sealin sealing g rings rings fro from m the the rear rear cover cover.. Remove Rem ove the 2-4 acc accumu umulat lator or ass assemb embly ly fro from m the the rear rear cov cover. er.
19.
Remove the Remove the (3) (3) bolts bolts holdi holding ng the the one way way clut clutch ch inner inner race race to to the case case.. Note Note the O-rings on the larger bolts.
20.
Remove the oil pipes.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
10
Jatco 5 Speed
21. 21. 22.
Remove Remo ve th the e sp spee eed d se sens nsor or bo bolt lts. s. Remove Rem ove the spe speed ed sens sensor or and and the rea rearr cover cover to mai main n case case seal seal..
23.. 23
Remo Re move ve the the dir direc ectt cluc cluch h accu accumu mula lato torr asse assemb mbly ly..
24.. 24
Remo Re move ve th the e 2-4 2-4 clu clutc tch h pis pisto ton n ret retur urn n spr sprin ing. g.
25. 25. 26.. 26
Remove Remo ve th the e Rev Rev/H /Hig igh hc clu lutc tch h dru drum m bea beari ring ng.. Remo Re move ve th the e Rev Rev/H /Hig igh h clu clutc tch h dru drum. m.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 27. 28.
Remove the clu Remove clutch tch hub to Rev Rev/Hi /High gh clu clutch tch dru drum m bear bearing ing.. Remove Rem ove the clu clutch tch hub an and d the the clutc clutch h hub hub to sun she shell ll bear bearing ing..
29. 30.
Remove the sun she Remove shell ll and and the sun she shell ll to plan planet et bea bearin ring. g. Remove Rem ove the fro front nt plan planet et and and the the plan planet et to to sun sun gear gear bear bearing ing..
31. 32.
Remove the sun gea Remove gearr and and the the sun sun gear gear to rea rearr plane planett beari bearing. ng. Remove Rem ove the rea rearr plane planett and and the the rear rear plan planet et to to ring ring gear gear bea bearin ring. g.
11
2005 ATRA. All Rights Reserved. Printed in U.S.A.
12
Jatco 5 Speed
33.
Remove Rem ove the rea rearr ring ring gear gear an and d the the ring ring gear gear to Low Low drum drum bea bearin ring. g.
34.
Remove Rem ove the Lo Low w Drum Drum and the Low dru drum m to to case case bea bearin ring. g.
35.. 35
Remo Re move ve th the e 2-4 2-4 clu clutc tche hes s (3) (3) an and d ste steel els s (4) (4).. No t e : There are (2) 2-4 steel plates back to back next to the snap ring.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
13
For this next step a special tool needs to be used. A speicial tool can be fabricated out of a piece of flat steel or a piece of bar stock. A long bolt or a length of all-thread is required as well. The bar stock needs to 7-7 1/4 inches inches long with with a hole drilled drilled in the middle middle large enough for the bolt or the all thread to pass easily through the tool. The long bolt shown is from from Kent-Moore Kent-Moore tool # J-23327-1. J-23327-1.
36.
Using the Using the specia speciall tool tool compre compress ss the the low/re low/rever verse se pisto piston n and remo remove ve the the retaining snap ring. No t e : The opening of the snap ring has curved ends and only fits into the case one way.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
14 37.
Jatco 5 Speed
Remove the Remove the low/ low/rev rev clut clutche ches s (6) and and steel steel plat plates es (7). (7). Note Note the the positi position on of of the dished plate for reassembly.
T op
38.
Remove the Remove the low/ low/rev rev spra sprag g retain retaining ing sna snap p ring ring and the the low/ low/rev rev spra sprag. g. Note Note the position of the snap ring opening for reassembly.
39. 39. 40.
Remove Remo ve th the e ser servo vo co cove verr sna snap p rin ring. g. Remove Rem ove the ser servo vo cove coverr by blo blowin wing g shop shop air air into into the por portt show shown. n.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
15
WARNING! On the right is the original servo cover that was removed from this transmission. This cover was stuck in the bore. No amount of air pressure was going to force this cover out of the bore. Breaking the the cover apart was was the only solution.
The Cause The problem is co corrosion rrosion between the the lip of the the servo cover and the the transmission case.
Th e S oluti on Prior to assembly run a bead of silicone around the servo just below the lip. This will keep out moisture and prevent corrosion. corrosion.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
16
Jatco 5 Speed
S u ba bass s em embl blyy R ebu ebuii l d P r oc oced edu ur e Fr ont Pump: Di sas sem semb bly An d Ass emb mbly ly 1. 2.
3. 4. 5.
Remove Remo ve (8 (8)) 5mm 5mm al alle len n bol bolts ts an and d spl split it th the e pum pump p hal halve ves s apa apart rt.. Remove th the pu pump gea gearrs fr from th the bo body.
Clean an and dr dry al all pu pump co components. Insp In spec ectt the the pu pump mp ge gear ars s and and th the e pum pump p poc pocke kett for for we wear ar an and d scor scorin ing. g. Inspec Ins pectt the the sta stator tor sup suppor portt half half for wea wearr and and sco scorin ring. g. Ins Inspec pectt the the bus bushin hing g for for wear.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
17
6.
Instal Inst alll a new pu pum mp bu bush shiing and sea eall. No t e : The step in the bushing is in stalled towards the gear.
7.
Lightl Ligh tly y lube lube the the pum pump p pock pocket et and and in inst stal alll the the pum pump p gear gears. s. Use Use a sm smal alll amount of assembly gel to keep the pump gears centered in the pocket. Instal Ins talll the the sta stator tor sup suppor portt onto onto the pum pump p body body.. Inst Install all the (8) 5mm bol bolts ts and tighten them to 96 in. lbs.
8.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
18
Jatco 5 Speed
R eve verr se/ se/Hi Hi g h Clutch D r um: Teardown And As sem semb bly 1. 2.
Remove Remo ve the the rev rever erse se clu clutc tch h reta retain inin ing g snap snap ri ring ng and and the the re reve vers rse e clut clutch ch pressure plate. Remo Re move ve (2 (2)) re reve vers rse e cl clut utch ches es an and d (2) (2) re reve vers rse e st stee eell pl plat ates. es.
3. 4.
Remove Remo ve tthe he di dire rect ct cl clut utch ch re reta tain inin ing g sna snap p rin ring g and and pr pres essu sure re pl plat ate. e. Remo Re move ve the the (5) (5) dir direc ectt clu clutc tche hes s and and (5 (5)) dir direc ectt ste steel els. s.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 5. 6. 7.
19
Using Usin g a suit suitab able le pre press ss,, comp compre ress ss the the pis pisto ton n retu return rn spr sprin ing g and and remo remove ve the the retaining snap ring. Remo Re move ve the the ret retai aine ner, r, ret retur urn n spri spring ngs s and and the the pist piston ons s from from the the dru drum. m. Rem Remov ove e and discard the piston seals. Clea Cl ean n an and dry dry all re rev/ v/h hi clu cluttch dr dru um par partts.
Caution Carefully inspect the reverse piston. The piston can crack. The crack is very difficult to see. If the clutches in the drum are burnt, ALWAYS replace the reverse piston. The Mazda part number is FP03-19-480.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
20
Jatco 5 Speed
8. 9.
Instal Inst alll new new seal seals s on th the e pist piston ons s and and inst instal alll the the pist pistin ins s into into the the dru drum. m. Usin Us ing g a sui suita tabl ble e pres press, s, co comp mpre ress ss the the spr sprin ing g reta retain iner er and and in inst stal alll the the retaining snap ring.
10. 11.
Installl the Instal the (5) dir direct ect clu clutch tches es and (5) ste steel el pla plates tes.. Instal Ins talll the the pressur pressure e plate plate and and the reat reatini ining ng snap snap ring. ring. Dir Direct ect clut clutch ch clearance should be .031-.043 in. and is adjusted by changing the pressure plate.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
21
12. 13.
Installl the Instal the (2) rev revers erse e clutc clutches hes and (2) ste steel el pla plates tes.. Instal Ins talll the the reverse reverse pres pressur sure e plate plate and and the reta retaini ining ng snap snap ring. ring. Reve Reverse rse clutch clearance should be .020-.030 in. and is adjusted by changing the pressure plate.
14.
Installl (3) seal Instal sealing ing ring rings s onto onto the the rear rear cover cover and and place place the the drum drum onto onto the the rear rear cover to air check the clutch drum.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
22
Jatco 5 Speed
Di r ect Clutch Dr um: Tear Tear do down wn and Ass emb mbly ly 1.
Remo Re move ve the the di dire rect ct cl clut utch ch re reta tain inin ing g sna snap p rin ring g and and pr pres essu sure re pl plat ate. e.
2.
Remo Re move ve th the e (4) (4) di dire rect ct cl clut utch ches es an and d (4) (4) st stee eell pla plate tes. s.
3.
Using Usin g a sui suita tabl ble e pres press, s, co comp mpre ress ss the the spr sprin ing g reta retain iner er and and re remo move ve the the retaining snap ring. Remo Re move ve th the e ret retai aine ner, r, re retu turn rn sp spri ring ng an and d the the pi pist ston on..
4.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
23
5. 6
Remove Remo ve tthe he spr sprag ag rret etai aini ning ng sna snap p ring ring and and the the spr sprag ag ret retai aini ning ng was washe her. r. Remove th the s sp prag an and tth he ne needle be bearing.
7. 8. 9.
Clean Clea n and and dr dry y all all di dire rect ct cl clut utch ch dr drum um co comp mpon onen ents ts.. Insp In spec ectt the the spr sprag ag ra race ce and and the the spr sprag ag el elem emen ents ts fo forr wear wear an and d scor scorin ing. g. Inst In stal alll the the be bear arin ing g and and th the e spr sprag ag in into to th the e dru drum. m. No t e : The lip on the sprag faces up. Inst In stal alll the the re reta tain iner er an and d the the sn snap ap ri ring ng..
10.. 10
2005 ATRA. All Rights Reserved. Printed in U.S.A.
24 11. 12.
13. 13. 14.
Jatco 5 Speed
Installl new sea Instal seals ls onto onto the the piston piston.. Light Lightly ly lube lube the the seals seals and and instal installl the the piston into the drum. Using Usi ng a suita suitable ble pres press, s, compr compress ess the the return return spri spring ng and and instal installl the retai retaini ning ng snap ring.
Instal Inst alll (4) (4) dire direct ct clu clutc tche hes s and and (4) (4) stee steell plat plates es.. Instal Ins talll the direc directt clutch clutch pres pressur sure e plate plate and and the retai retainin ning g snap snap ring. ring. Direc Direct t clutch clearance should be .040-.080 in. and can be adjusted by changing the pressure plate.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
15. 16.
25
Installl the Instal the inner inner spr sprag ag race race int into o the the sprag sprag to air air chec check k the the drum drum.. The spr sprag ag rac race e shou should ld fre freewh ewheel eel cou counte nterr cloc clockwi kwise. se.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
26
Jatco 5 Speed
Low Clutch Dr um: Teardown and As sem semb bly 1. 2.
Remove Remo ve the the rret etai aini ning ng sna snap p ring ring an and d the the low low clu clutc tch h pres pressu sure re pla plate te.. Remo Re move ve th the e (7) (7) Low Low clu clutc tche hes s and and (7 (7)) ste steel el pl plat ates es..
3.
Using Usin g a sui suita tabl ble e pres press, s, com compr pres ess s the the spri spring ng ret retai aine nerr and and remo remove ve the the sna snap p ring. Remo Re move ve the the ret retai aine ner, r, re retu turn rn sp spri ring ng an and d the the low low pist piston on..
4.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
27
5. 6.
Clean Clea n an and d dry dry al alll llow ow cl clut utch ch dr drum um co comp mpon onen ents ts.. Insp In spec ectt the the sp spra rag g rac race eo on n the the dr drum um fo forr wea wearr and and sc scor orin ing. g.
7. 8.
Instal Inst alll new new se seal als s on on the the pi pist ston on an and d spr sprin ing g ret retai aine ner. r. Lightl Lig htly y lube lube the the pis piston ton and ins instal talll the the pist piston on,, retur return n spri spring ng and and reta retaine inerr into into the low drum. Usin Us ing g a suit suitab able le pre press ss,, comp compre ress ss the the ret retur urn n spri spring ng and and ins insta tall ll the the sna snap p ring.
9.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
28
Jatco 5 Speed
10.. 10
Inst In stal alll the the di dish shed ed sp spri ring ng pl plat ate e as as sho shown wn..
11. 11. 12.
Instal Inst alll (7) (7) low low cl clut utch ches es and and (7 (7)) stee steell plat plates es.. Instal Ins talll the low low press pressure ure plat plate e and snap snap ring. ring. Low Low clutc clutch h cleara clearance nce shou should ld be .044-.051 in. and is adjusted by changing the pressure plate.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
29
Planetar Plane tar y Gear Gear S ets Inspect the planetary gear sets for gear wobble and broken or cracked teeth. If any are damaged or worn the planetary gear set must be replaced.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
30
Jatco 5 Speed
Tr ansf er Gear / R educti on Gear: T ear do down wn An d Ass emb mbly ly 1.
Rem emo ove th the e loc lock k nu nut on on th the tra trans nsffer sh sha aft.
2.
Us Usin g a sui suita tabl ble e and press, pres s, suppo port rt the thegear. idler idl er gea gearr and and pres press s the the shaf shaftt thro throug ugh h theing bearing race thesup reduction
3. 4. 5.
Clean Clea n and and dr dry y all all tr tran ansf sfer er ge gear ar/r /red educ ucti tion on ge gear ar co comp mpon onen ents ts.. Insp In spec ectt the the id idle lerr gea gearr (la (larg rge e gea gear) r) be bear arin ings gs fo forr wea wearr and and sc scor orin ing. g. Insp In spec ectt the the redu reduct ctio ion n gear gear pla plane neta tary ry gea gearr set set for for gear gear wob wobbl ble e and and brok broken en or or cracked teeth.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 6. 7.
8. 9.
31
Place Plac e the the idle idlerr gear gear ont onto o the the reduc reducti tion on gea gearr shaf shaft. t. Usi Using ng a sle sleev eve e star startt the the bearing onto the the shaft. Plac Pl ace e the the redu reduct ctio ion n gear gear ont onto o the the shaf shaft. t. Usi Using ng a sl slee eeve ve sta start rt the the gea gearr onto onto the shaft.
Press Pres s tth he g gea earr and and th the e bea beari rin ng in into pl plac ace. e. Press th the be bearing ra race in into pl place.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
32
Jatco 5 Speed
10.
Tighten the nut Tighten nut onto onto the reduc reduction tion shaf shaftt until until 5-15 in. lbs. of turni turning ng torqu torque e is obtained.
11.. 11
Sta take ke the nut in into to pl pla ace ce..
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
33
R ear Co Cove verr : T ear do down wn A nd A ssemb ssembly ly 1. 2. 3. 4.
Remov Rem ove e th the Remo Re move ve th the e Remo Re move ve th the e Remove the
pis p isto ton n and and di disc sca ard the se sea als ls.. accum acc umul ulat ator or co cove verr ret retai aini ning ng sn snap ap ri ring ng.. accum acc umul ulat ator or co cove ver, r, th the e spr sprin ing g and and th the e pis pisto ton. n. three sealing rings.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
34 5. 6. 7. 8. 9. 10.. 10 11.
Jatco 5 Speed
Cle lea an and and dr dry y al all rea rearr co cove verr co compo pon nen entts Insp In spec ectt the the accu accumu mula lato torr bord borde e for for wear wear.. The The bore bore sho shoul uld d be smo smoot oth h and and free from any scoring. Inst In stal alll new new seal seals s on the the 2-4 2-4 pis pisto ton. n. Lig Light htly ly lub lube e the the seal seals s and and inst instal alll the the piston into the rear cover. Instal Ins talll (2) (2) new tef teflon lon sea sealin ling g ring rings s onto onto the acc accum umula ulator tor pis piston ton and ins instal talll the piston into the rear cover. Inst In stal alll the the sp spri ring ng an and d the the ac accu cumu mula lato torr cov cover er wi with th a new new OO-ri ring ng.. Inst In stal alll the the re reta tain inin ing g sna snap p rin ring. g. Instal Ins talll (3) (3) new new sea sealin ling g rings rings wi with th the the V-cu V-cutt as as shown shown..
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
35
Valve B ody: T ear do down wn A nd As semb sembly ly There are two vavle vavle body configurations configurations for this transmission. transmission. The Mazda Mazda valve body and the the Volkswagen/ Volkswagen/Jaguar. Jaguar. These valve as bodies are NOT interchangeable. The Jaguar valve body is the same the Volkswagen except that it has one less checkball. Ca Cau u t i o n : Some of the valves in both valve bodies are teflon teflon coated. DO NOT use abrasives on these valves. If the valves are worn or become sticky in the bores the valve valve body may need to be replaced.
Ma z da
VW/JJ aguar VW/
2005 ATRA. All Rights Reserved. Printed in U.S.A.
36
Jatco 5 Speed
Ma z d a V a l ve B od ody y
ID 1 2 3 4 5 6 7
Description Modifier Ac Accumulator Va Valve Pressure Mo Modifier Va Valve To Torq rque ue Conv Conver erte terr Pre Press ssur uree Reg Regul ulat ator or Valv Valvee Throttle Accumulator Valve A Accumulator Valve A Throttle Accumulator Valve C Accumulator C Co ontrol Valve C
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
37
Ma z d a V a l ve B od ody y
ID
Description
1 2
Failsafe Valve Shift Valve A
3
Reverse Inhibit Valve
4
Neutral Control Valve
5
Accumulator Switch Valve
6
Pilot Valve
7
Manual Valve
8
Neutral Shift Valve
9
TCC Control Valve
10
Shift Valve B
11
Plug
2005 ATRA. All Rights Reserved. Printed in U.S.A.
38
Jatco 5 Speed
Ma z d a V a l ve B od ody y
ID 1 2 3 4 5 6 7 8 9
Description Shift Valve C Low Cl Clutch Ac Accumulator High Clutch Accumulator Throttle Ac Accumulator B Accumultor Valve B Press ssu ure Regulator Valve Line Pr Press ssu ure Re Relief Va Valve Reduction Ti Timing Va Valve Reduction Reducing Valve
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
39
Ma z d a C h eck ba ball l L oc oca a t i on onss 4 S te tee el Check balls
5 P l a s t i c C h eck ba ball l s
2005 ATRA. All Rights Reserved. Printed in U.S.A.
40
Jatco 5 Speed
Volk Vo lk swag en/ n/JJ ag uar Valv Valve e bo body
ID 1 2 3 4 5 6 7
Description Modifier A Acccumulator Pressure M Mo odifier V Va alve To Torq rque ue Co Conv nver erte terr R Reg egul ulat ator or Va Valv lvee Thr hrot ottl tlee A Acccum umul ulat ator or Val alve ve A Accum umul ulat ator or Con ontr trol ol Val alve ve A Unknown Unknown
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
41
Volk Vo lk swag en/ n/JJ agu ar Valv Valve e bo body
ID 1 2 3 4 5 6 7 8 9 10 11
Description Shift Valve C Low Clutch Accumulator High Cl Clutch Ac Accumulator Throttle Ac Accumulator Unknown Accumulator Co Control Va Valve B Unknown Pressure Regulator Valve Line Pressure Relief Valve Reduction Ti Timing Va Valve Reduction Reducing Valve
2005 ATRA. All Rights Reserved. Printed in U.S.A.
42
Jatco 5 Speed
Volk Vo lk swag en/ n/JJ ag uar Valv Valve e bo body
ID 1 2 3 4 5 6 7 8 9 10
Description Shift Valve A Reverse Inhibit Valve Neutral Co Control Va Valve Accumulator Switch Valve Pilot Valve Manual Valve Neutral Shift Valve TCC Control Valve Shift Valve Failsafe Valve
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
43
Volk Vo lk swag en/ n/JJ agu ar Valv Valve e bo body
4 S te tee el Check balls
5 P l a s t i c C h eck ba ball l s
J a g u a r H a s N o Ch C h eck ba ball l H er e
2005 ATRA. All Rights Reserved. Printed in U.S.A.
44
Jatco 5 Speed
Tr ansmis si on Case: Assemb Assembly 1.
2.
Remo Re move ve the the man manua uall leve leverr dete detent nt spr sprin ing. g. Dri Drive ve out out the the (2) (2) rol rolll pins pins hol holdi ding ng the rooster comb and park linkage. Remove the manual linkage retaining retaining bolt. Replac Rep lace e the the ma manu nual al lev lever er sea seall and and rei reinst nstal alll the the man manual ual lin linkag kage e comp compone onents nts..
No t e : Before installing the retaining bolt be sure to aligin the park linkage.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
45
3.
Place Plac e a 1 1/4 1/4 in. in. 12 12 poin pointt sock socket et ove overr the the spli spline nes s to che check ck the the out outpu putt gear gear turning torque. Turning torque should be 5.6- 11.5 in. .lbs.If not as specified replace the output gear bearing assembly.
4.
Inst In stal alll (2) (2) low low clut clutch ch dru drum m seal sealin ing g ring rings. s. Ret Retai ain n with with ass assem embl bly y gel. gel.
5. 6.
Instal Inst alll (2) (2) se seal alin ing g rin rings gs on onto to th the e one one wa way y clu clutc tch h inn inner er ra race ce.. Instal Ins talll new new O-r O-ring ings s onto onto the (2) lar large ge bol bolts ts and ins insta tall ll the spr sprag ag rac race e into into the case. Torque the bolts to 24-28 ft. lbs.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
46
Jatco 5 Speed
7. 8.
Instal Inst alll the the low/ low/re reve vers rse e spra sprag g into into the the cas case e with with the the smo smoot oth h side side fac facin ing g up. up. Instal Ins talll the the ret retain aining ing sna snap p ring ring in into to the cas case. e. Not Note e the the loc locati ation on of the sna snap p ring opening.
9. 10.. 10
Instal Inst alll tthe he lo low/ w/re reve vers rse e clu clutc tche hes s (6) (6) an and d ste steel el pl plat ates es (6 (6). ). Inst In stal alll the the dish dished ed pl plat ate e as as show shown. n.
T op
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
47
11. 12.
Installl tthe Instal he low low/re /rever verse se ret return urn spr spring ing sea seatt and and spr spring ing.. Instal Ins talll the the low/re low/rever verse se pis piston ton an and d pist piston on hou housin sing. g.
13.
Using the Using the special special tool tool made made duri during ng tran transmi smissi ssion on teard teardown own,, compre compress ss the low/reverse piston housing and spring assembly. Instal Ins talll the retai retainin ning g snap snap ring. ring. Note Note the the locati location on of the the snap snap ring ring openi opening. ng.
14.
15. 16.
Using assem Using assembly bly gel, gel, inst instal alll the low low cl clut utch ch to case case bear bearing ing on on the the low drum drum.. Using Usi ng a twis twistin ting g motion motion inst instal alll the low low d drum rum dow down n into into the case case.. The drum drum should feewheel counterclockwise.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
48 17. 18.
Jatco 5 Speed
Installl the Instal the bearin bearing g down down into into the drum drum and and stick stick the the beari bearing ng to the the rear rear ring ring gear with assembly gel. Install the ring gear down into the drum. Instal Ins talll the the bearin bearing g down down into into the rin ring g gear gear and and stick stick the the race race to the rea rear r planet with assembly gel. Install the planet down into the ring gear.
19. 20.
Installl the Instal the sun gear gear to to planet planet bear bearing ing down down into into the the plane planet. t. Insta Install ll the the sun gear into the planet with the smooth surface facing down. Stick Sti ck the the front front plane planett to sun sun gear gear bearin bearing g onto onto the plan planet et using using asse assembl mbly y gel and install the planet down onto the sun gear.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 21. 22.
49
Installl the bear Instal bearing ing onto onto the plan planet et and and stick stick the the race race onto onto the sun sun shell shell with with assembly gel. Install the sun shell down onto the planet. Instal Ins talll the the (3) 2-4 clu clutch tch pla plates tes and (5) ste steel el pla plates tes..
23.
Installl the high Instal high clu clutch tch bear bearin ing g race race onto onto the sun sun shell shell and and stick stick the the high high clutch hub bearing to hub using assembly gel.
24.
Installl the high Instal high clu clutch tch hub hub to to high high clutch clutch race race dow down n into into the hub. hub. Sti Stick ck the bearing to the high drum with assembly gel and install the high drum down onto the hub.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
50
Jatco 5 Speed
25. 26.. 26
Installl th Instal the e high high clutc clutch h to rear rear cove coverr bearin bearing g down down into into the the drum drum.. Inst In stal alll th the e 2-4 2-4 pi pist ston on re retu turn rn sp spri ring ng..
27.
Instal Ins talll new sea seals ls on the the accum accumula ulator tor pist piston on and and cover cover and and Instal Installl the the accumulatorr assembly into the case. accumulato
28.
Ins Instal talllsensor. the speed the speed sensor sensor w iring ngtoloom loom into the the case case and instal and installl the inpu input t speed Install thewiri case rear into cover seal (arrow).
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
51
29.. 29
Inst In stal alll th the e (3 (3)) oi oill tu tube bes s
30.
Using an H gauge Using gauge check check the the endpl endplay. ay. Pla Place ce the the gauge gauge on the the trans transmis missio sion n case and set the plunger down onto the high clutch bearing.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
52 31.
Jatco 5 Speed
Flip the H gauge Flip gauge ove overr onto onto the the rear rear cove cover. r. When When the was washer her is in pla place ce the the end clearance should be .010 - .020 in. and is adjusted by changing the bearing race.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
53
32.
Place the Place the end cove coverr onto onto the tran transmi smissi ssion on case. case. Ther There e will will spring spring tens tension ion on the cover. Tighten the end cover bolts down evenly and torque the bolts to 14 - 16 ft. lbs.
33.. 33
Repl Re plac ace e the the OO-ri ring ngs s on on the the la larg rger er bo bolt lts. s.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
54
Jatco 5 Speed
34.
Instal Ins talll the the spee speed d senso sensors rs and and the TFT sen sensor sor int into o the the case case..
35.. 35
Instal Inst alll the the se serv rvo o int into o the the ca case se.. Note : It is very important to loosen the lock nut on the servo prior to installatio installation. n.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 36.. 36
Inst In stal alll the the di dire rect ct dr drum um do down wn in into to th the e cas case. e.
37.
Instal Ins talll the band band dow down n into into the case case.. While While hold holding ing the the band band in posi positio tion, n,
55
screw the band anchor bolt, from the outside of the case, into the slot in the band. N o t e : Add thread sealer to anchor bolt prior to installation to prevent leaks.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
56
Jatco 5 Speed
38.
Installl the Instal the sun gear gear bear bearing ing down down into into the the cente centerr of the the reduct reduction ion drum drum and secure the race to the sun gear with assembly gel. Install the sun gear down into the reduction drum.
39.
Installl the reduc Instal reductio tion n gear gear assemb assembly ly down down into into direc directt clutch clutch.. The reduc reductio tion n gear assembly is all the way down into the drum when the reduction gear is flush with the output gear. Install Insta ll (3) (3) new new seali sealing ng rings rings onto the inpu inputt shaft shaft and insta install ll the the input input shaf shaft t into the transmission.
40.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 41.
57
42.
Installl a new fron Instal frontt pump pump gasket gasket and and instal installl the front front pump pump.. Torque Torque the the fron front t pump bolts to 14-16 ft. lbs. Instal Ins talll a new inp input ut shaf shaftt O-ring O-ring,, front front pump pump O-rin O-ring g and and a new filt filter. er.
43.. 43
Inst In stal alll th the e fi fin nal dri rive ve..
J a g u a r A W D VW/Mazda
2005 ATRA. All Rights Reserved. Printed in U.S.A.
58
Jatco 5 Speed
44.
Thouro Tho urough ughly ly clean clean and and dry dry the the two magn magnets ets and and insta install ll them them into into the the case. case.
45.
Flatt file Fla file the bell bell housi housing ng to knock knock down down any any high high spots spots prior prior to insta installa llatio tion. n.
46.
Lightly Light ly lube lube the the pump pump O-ring O-ring and and apply apply a bead bead of of sealer sealer to to the b bell ell hous housin ing. g. Install the bell housing onto the transmission case. Tighten all bolts to 20-22 ft. lbs.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 47.. 47
Inst In stal alll two two ca case se to va valv lve e bod body y sea seals ls
48.
Air Check pas passages.
59
2005 ATRA. All Rights Reserved. Printed in U.S.A.
60
Jatco 5 Speed
Valve Valv e B ody I nstallati on 47.
The manu manual al valve valve cann cannot ot be seen seen durin during g valve valve body body instal installat lation ion.. This This makes makes the installation rather tricky The Easy Way
Place the manual linkage in the manual low position. Slide the manual valve down into the valve body and lower the valve body onto the transmission case. Install two bolts only hand tight. When the manual manual valve is engaged onto the linkage the the manual valve can be seen sticking out of the valve body approx. 3/8 in. and will move in and out while rotating rotating the manual manual lever.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 48.
61
Connectt the Connec the speed speed senso sensorr harne harness ss and and the the soleno solenoid id harn harness ess plug plug-in -ins. s. Install the valve body bolts. It may be necassary to unplug the solenoid to install the valve body bolt below the wiring harness (arrow). Tighten valve body bolts to 60-72 60-72 in. lbs.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
62
Jatco 5 Speed
49.
Using Usi ng a new new sid side e cover cover gas gasket ket,, inst install all the sid side e cove cover. r.
50.
Ba n d a d j u s t me n t : Loosen the lock nut several turns. Screw the band adj
uster in until it bottoms out and back off 2 1/2 turns and tighten the lock nut down. N o t e : A 14mm crows foot may need to be modified to fit properly over the lock nut.
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed 51.
52.
Installl new seal Instal seals s on the the servo servo accum accumula ulator tor pist piston on and and the the servo servo cover cover.. Assemble the servo cover cover and install the snap ring.
Place a bead Place bead of sil silico icone ne arou around nd the the upper upper lip lip of the the servo servo cover cover (thi (this s will will prevent corrosion) and install the servo cover into the transmission.
63
2005 ATRA. All Rights Reserved. Printed in U.S.A.
64
Jatco 5 Speed
B ear i ng And R ace Lo Locatio cations ns
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed B ear i ng And R ace Lo Locatio cations ns
65
2005 ATRA. All Rights Reserved. Printed in U.S.A.
66
Jatco 5 Speed
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
67
2005 ATRA. All Rights Reserved. Printed in U.S.A.
68
Jatco 5 Speed
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
69
2005 ATRA. All Rights Reserved. Printed in U.S.A.
70
Jatco 5 Speed
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
71
2005 ATRA. All Rights Reserved. Printed in U.S.A.
72
Jatco 5 Speed
2005 ATRA. All Rights Reserved. Printed in U.S.A.
Jatco 5 Speed
73
2005 ATRA. All Rights Reserved. Printed in U.S.A.
74
Jatco 5 Speed
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