SPRING 2006 VOL. 7 ISSUE 1
News and Tips for the Rebuilder from Transtar Industries, Inc.
Transtar—Building Success for the Rebuilder While conditions in the transmission rebuilding industry change with the addition of more and newer transmissions, fewer repair orders overall, and the advent of OE exchange remanufactured units, there is one thing that will never change—Transtar Industries’ commitment to supporting the rebuilder. “Building our business by helping you build yours” is more than just words, it’s a promise by every member of our organization to provide you with the products, service and knowledge that will help you stay on top. In this time of change, independent and franchise transmission shops must do what they do best—rebuild transmissions with the skill that only experienced, educated professionals possess. How can Transtar help? •
We offer the broadest product line in the business. Transtar stocks over 15,000 OE quality transmission products every day so you can be assured that when you call us, we’ve got what you need.
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We offer the highest quality products from the best manufacturers. Transtar partners with the most respected manufacturers in the industry to provide OE quality transmission parts that meet the highest quality standards—yours. We offer the best names in the business so you’ll be proud to put your name on every rebuild that leaves your shop.
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We know the value of continuing education. Transtar is involved with and supports ATSG and ATRA through sponsorship of seminars and knowledge sharing with ATSG and ATRA experts so your rebuilders have access to the latest information and education affecting our industry. There’s no substitute for up-to-date information.
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We are expanding to serve you better. Transtar is adding delivery routes and locations so we can get to you faster. We know that you expect to receive your parts in a timely manner, and we’re constantly working to improve delivery times and local accessibility to our full product line.
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We know the value of service. Transtar is proud to have the most dedicated sales force in the transmission industry. Our sales reps are knowledgeable, dependable, and committed to making it easy for you to get the products you need. We want to be your first call—every time—and our representatives will bend over backward to prove it. Please call your Transtar rep today and give us the opportunity to continue to prove how much we value your business.
As the premier provider of transmission products for over 30 years, Transtar Industries is the one company you can count on to help you conquer market challenges, stay on the cutting edge of product and technology developments, and succeed for years to come. Together, we can make 2006 another great year for our industry.
Michael A. Sotak President and COO
Authorized Distributor
TRANSTAR LAUNCHES CUSTOMER-CENTERED WEB SITE
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Transtar Industries, Inc. announced the launch of its re-designed web site on February 9, 2006, www.transtarindustries.com. The key objective in re-designing the company’s web site is to make it easier than ever for customers to find and use the information they need to run their businesses successfully. Our new site, makes it simple for customers to find information on products, promotions, technical and product information, seminars, and catalogs, gives users immediate access to the information that’s important to them. There are several new features to the site that make doing business with Transtar Industries especially easy for customers:
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Electronic Catalog. Transtar’s popular electronic catalog (e-cat) is now available for download directly from the web site. Customers no longer have to request the e-cat on disk from Transtar, they can simply go out to the web site and download it onto their hard drives.
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UPS shipment tracking. Customers can track their orders by clicking on the UPS Track Shipments icon at the bottom of the home page.
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Promotions section. This new section features all current promotions, making it easy for customers to find the latest specials and new product introductions.
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Online credit application. New customers can now access Transtar Industries’ credit application online. The application can be downloaded from the web site, completed, then faxed or e-mailed back to Transtar for approval.
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International section. For the first time, international customers will find content that addresses their specific needs, like shipping methods and transit times to major cities around the globe, payment options, and international division contacts.
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Technical section. The new Technical section of the web site features TransTalk product bulletins and product application updates that cover product news and transmission information created by Transtar’s product experts. Visitors to the site can download any of the product bulletins or updates archived in this section.
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Locations page. All Transtar branch locations are listed here, along with a map of locations, contact information for each branch, maps to each location, and a location finder.
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Subscribe function. Visitors to the Transtar web site can now elect to subscribe to receive newsletters, promotional flyers, and technical and product updates via e-mail or regular mail.
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Manufacturers page. The new Manufacturers page on the web site features an interactive transmission whose sections light up when a user mouses over the list of manufacturers featured to indicate what part(s) of a transmission they manufacture. There is also a link to each manufacturer’s web site from this page.
The new site will be updated frequently to keep the content fresh and our customers coming back. Check back regularly to see the latest information.
Use your American Express® Card at Transtar Industries and earn double Membership Rewards® Points It Pays to Order from Transtar! Use Your American Express Card at Transtar from March 1 – April 30, 2006 and Double Your Rewards! Transtar Industries, Inc. is the one-stop transmission parts supplier for all your transmission needs. For over 30 years, Transtar has been the automotive transmission repair industry’s most trusted source for OE quality parts, outstanding service, product support, and on-time delivery. With locations throughout the U.S., Puerto Rico and Canada, one-stop transmission parts shopping starts here! Earn DOUBLE Membership Rewards Points on all your Transtar purchases from March 1 – April 30, 2006 when you use your eligible, enrolled American Express® Card. Only available to U.S. Membership Rewards enrollees.
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Got Gears? (Here come the 6-speeds) It seems like only yesterday that 5-speed automatics were the talk of the town. Although Nissan released the RE5R01A in 1991, it really never made it to the states whereas ZF, the cutting edge guys from Germany, did make it here in 1991 with the 5HP30. The bulk of the 5-speeds however, did not show up until the late 1990’s including the Ford 5R55E, the Toyota (Lexus) A650E and the GM Straussburg 5L40E to name a few.
(But that was then and this is now.) Based on the premise that more is better the automotive transmission engineering community has determined that 6-speeds are just peachy and have released several. The focus of this article will be on the ZF6HP26, Ford’s 6R60 and the GM 6L80(E). Although the basic design of these models stem from ZF, which launched their version first, Ford and GM did change certain components to fit their criteria. From a complexity standpoint these transmissions are not overwhelming and anyone that has rebuilt an AODE will certainly recognize the planetary arrangement and power flow. Engineers were able to achieve 6-speeds with using only five clutch packs, no bands and with the exception of GM, no one-way clutches. The clutch-to-clutch shifting is provided by seven or eight solenoids depending on manufacturer and there is, of course, a lock-up converter. Most of the components are normal automatic transmission design stuff, however, the electrical controls continue to evolve and the units do have adaptive learn computer strategy which provides the ability to change parameters according to driving habits. Externally, the 6-speed models will vary in appearance based on manufacturer, model, engine size, and whether it’s a 2-wheel drive or a 4-wheel drive vehicle. The electrical hookups are somewhat similar including the multiwire case connector. Torque converters will vary as well. Terminology differs between ZF, Ford and GM, which will tend to complicate matters when ordering parts or obtaining and applying diagnostic information. A simple item such as the primary input clutch is called the “A” clutch by ZF, the forward clutch by Ford and the 1-2-3-4 clutch by GM. The following is an overview of the internal components:
Pump – The 6HP26 and 6R60 pumps are basically the same. They are gear type pumps using a regular body and cover. Instead of a converter bushing there is a caged bearing to ride on the converter hub. The 6L80E is typically GM meaning that it is a variable displacement rotor/vane type pump. The rotor/slide components fit into a pocket in the bell housing and specific valves fit in the pump cover. GM uses a converter bushing. The most unique feature of the pump is that the sealing ring side of the pump cover is splined at the end. Fig. 1 The splines serve to anchor the front planetary sun gear to provide reduction. The front planet is what sets the 6-speed apart from Fig. 1 an AODE.
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A 5-speed could have merely begun as a 4-speed but with updated computer strategy or it could have been a brand new box.
By Mike Riley Technical Services Director
Clutch Packs – There are three rotating clutch packs and two stationary brakes consisting of normal components (i.e. frictions, steels, pistons, etc.) Input Clutch – The first rotating clutch to discuss, which is directly behind the pump, is the main input clutch (i.e. “A” clutch, forward clutch, 1-2-3-4 clutch.) What’s unique about this clutch is that the front planet is splined to the housing and is driven by the planet, not directly by the input shaft. The “A” clutch is always driven in reduction mode by the planet. GM differs from ZF and Ford in that the reverse clutch is integral in the “A” clutch housing whereas ZF and Ford uses two separate housings. Fig. 2 The ZF and Ford models use a hub from Fig. 2 the “A” housing to the reverse clutch. All three models function the same concerning power flow. The ‘A” clutch drives the forward sun gear (AODE term). GM ZF/FORD Reverse Clutch – The next rotating clutch in the stack up would normally be considered the reverse clutch or reverse/3rd clutch. The ZF, Ford and GM lingo for this clutch is “B” clutch, direct clutch, or 3-5 clutch, respectively. As previously stated ZF and Ford use a separate housing for this clutch pack whereas the GM version locates the 3-5 clutch into the 1-2-3-4 (“A” clutch) housing. ZF and Ford models use frictions and steels, which look similar throughout the transmission, whereas GM offers more of a variety. The “B” clutch drives the reverse sun gear (AODE term).
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High Clutch – The last rotating clutch in the line up would be comparable to a high gear clutch in an AODE. ZF, Ford and GM call this clutch assembly the “E” clutch, overdrive clutch, and 4-5-6 clutch, respectively. The “E” clutch housing is what the turbine (input) shaft is splined to and is driven directly by the torque converter. A unique feature of the “E” clutch is that the front planet ring gear is attached to the housing which drives the front planet carrier. Although ZF, Ford, and GM “E” clutch assemblies are basically the same, GM does differ on one component, the hub. To eliminate noise/vibration during apply GM added a dampener to the inside of the hub. Fig. 3 The dampener has a friction ring on each side, which Fig. 3 absorbs vibration. The “E” clutch drives the rear planet carrier, as does the AODE direct clutch. 2nd Brake – The first of the stationary brakes to cover would normally be applied for 2nd gear. The OE terms for these brakes are ZF, (“C” clutch), Ford, (intermediate clutch), and GM, (2-6 clutch). The “C” clutch splines to the “B” clutch housing (ZF & Ford) or 3-5 hub (GM) and when applied will stop the housing/hub from turning. The hub is splined to the reverse sun gear (AODE term). When the “C” clutch is applied the reverse sun gear is held stationary forcing the rear planet to walk around it. The “C” clutch is located on the front side of the center support. Low/Reverse Brake – The last friction pack on the list is another stationary brake, which is applied in manual low and reverse. ZF refers to this brake as the “D” clutch whereas Ford and GM call it the low-reverse clutch. The “D” clutch is located on the backside of the center support and the frictions are splined to the rear planet. When applied, the “D” clutch holds the planet stationary to provide reverse or low. ZF and Ford differ from GM concerning low gear (1st). The 6L80E has a low sprag (of course) in conjunction with the “D” clutch. On ZF and Ford applications the rear planet is held only by the “D” clutch whereas the GM model uses the sprag to hold the planet stationary. Although the “D” clutch is applied in 1st gear initially on the 6L80E, it releases prior to the 1-2 upshift to provide a non-synchronous (clean) shift. A clutch-clutch shift can always exhibit overlap or spin-up. Connecting Hubs – The hubs that connect clutch packs to planetary components are stamped steel and the arrangement is fairly straightforward. As was previously discussed, the only unique feature is the GM “E” clutch hub, which has the dampener.
Planetaries – The front (input) planetary set is directly behind the pump and the sun gear is splined to the cover. The ring gear is attached to the “E” clutch housing and the planet is splined to the “A” clutch housing. It is merely a “simple” planetary set and only has one mode. The planet is effective in 1st through 5th gears. The rear (output) planetary set is a compound planetary (Ravigneaux) type with a forward and reverse sun gear like AODE. The ZF Fig. 4 and Ford rear planet differs from GM in that the friction plate spline doesn’t exist on GM. The GM planet has an internal spline, which meshes with the low sprag outer race. Fig. 4 The ZF and Ford long pinions are one ZF/FORD piece whereas the GM pinions are two-piece.
Fig. 5
Lastly, the ZF and Ford output ring gear is a wide one-piece design whereas GM has two narrow gears of different diameters. Fig. 5
Center Support – The main difference in center supports is that the GM support has the low sprag inner race spline and the ZF and Ford doesn’t. Use caution during assembly due to the tube seals in the case. There are four of them with different lengths. Valve Body – The valve bodies are, of course, a piece of work with a noticeable amount of stuff. There are several valves, springs, etc along with a ton of electrical. ZF and Ford valve bodies have seven solenoids and one extra opening just for luck. GM didn’t wait. The 6L80E has eight solenoids to start. They all have an elaborate MLPS (internal mode switch) and electrical connector combination. Don’t break it. The electrical case connector has a release tab for removal. There is also a valve body to pump suction/pressure seal that must be removed before the pump comes out. Oil Pan – Fig. 6 The quick lube guys will love Fig. 6 this. Although GM and Ford in their infinite wisdom uses ZF FORD a tin pan and removable filter, ZF doesn’t. Nope! ZF has an all-plastic pan with integral filter, which will make fluid/filter changes “really cheap”. Filling the trans or checking the fluid level is also a real chore not to mention the cost of the fluid. Use the right stuff.
Continued on next page
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Got Gears? - Continued from previous page
Listed at right is an application chart, which may help with diagnosis. There are few certainties in this business but one for sure – change! Why? Mercedes just released a 7speed and there is talk of 8-speeds. Break out the chauffeur’s license!
WHY? Why? I think I’ve asked myself that question more and more in the last few years than ever before. The more I tear down and see these new transmissions the more I ask WHY. Actually it is more like what the heck were you thinking. This time it concerns the people at Ford and the 5R55N transmission. For instance, since I’ve been in this business it was always that the flywheel (flex plate) was bolted to the crankshaft and the torque converter was bolted to the flywheel. I guess that wasn’t good enough for the 5R55N transmission because now there is a flex plate that bolts to the converter (an alignment tool
required) and the flex plate bolts to the flywheel that bolts to the crank. Confusing? It was for me, so I ordered the flex plate, flywheel, torque converter and alignment tool. ($$$) I wanted to know why a tool was needed and how the tool actually worked. The OTC OEM tool is big $$$ but thanks to the aftermarket there are now less expensive alternatives. There are four tools including the OEM version that I know of at this time. The OTC (OEM) is made of steel, two of the aftermarket ones are made of aluminum and
By Dave Hritsko Technical Services Coordinator
look similar to the OTC style. The fourth one is made of plastic and is its own design, not like the OTC version. They all seem to work ok and are less expensive than the OTC style. Transtar is going to carry the OEM, OTC style, Transtar number T-0519 for the customers who want OEM and one of the aluminum aftermarket versions, Transtar number T-0519N for those who want to save a few bucks. The tool is needed to align the flex plate to the converter. The 5R55S/W transmission does not need the tool, only the 5R55N, at least at this time. While on the subject of this family of units (A4LD, 4R44/55E, 5R55E, 5R55N, and 5R55S/W) there is another tool to be aware of. This tool is for the servo pin bore that seems to be wearing out and causing many problems. This tool allows you to bore the case and sleeve the worn bore. This will save money by not buying a new case. The servo pin bore repair kit for the A4LD/E is Transtar number T-9212 and for the 5R55N/S/W order part number T-9213. Replacement sleeves are also available; contact your sales person for all the kit and sleeve part numbers.
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NEW PARTS & PRODUCTS This 4F27E rear cover has been modified to fit Ford and Mazda applications. Mazda uses a cover with aluminum ring lands that wear out prematurely. This cover is the Ford style with steel ring lands, Transtar Part Number 88995-R. Directions are included for easy installation. Don’t forget Transtar carries a complete line of hard parts, from OEM new to our continually expanding line of remanufactured hard parts including our newest additions for the 5R110W transmission.
Transtar carries the standard pump gear kit for the A604 transmission, part number K72201. The oversized pump gear kit, part number K72201-OS, will also be available soon. Transtar continues to expand its line of valve body component fixes, remanufactured valve bodies, and valve body kits including the TransLab kit for the A4BF3, Hyundai 2000-Up transmission, Transtar part number 63D03. We have added a valve body reamer holding fixture, Transtar part number T-9120, to support certain VB Reamers during the repair process.
Transtar has recently added one-way clutches for the Mercedes 722.6 transmission, part numbers 55960E and 55960F, plus other late model applications such as part number 91960 and 91930 for the JF506E transmission and part numbers 41960M, 41960P, 41960R for the 5L40E transmission.
A new Overhaul Kit has been added for the RE5R05A, 2003-up transmission, Transtar part number K93900.
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2006 SEMINAR SCHEDULE ATRA CHAPTER SEMINARS 4/8/06 4/15/06 4/22/06 5/13/06 5/13/06 5/20/06 5/20/06 6/10/06 6/17/06 8/5/06 9/9/06 9/16/06 10/14/06 10/21/06
Bloomington, MN Salt Lake City, UT Florence, AL Denver, CO Fremont, CA Anchorage, AK Los Angeles, CA Vancouver, BC Coeur d’Alene, ID Albuquerque, NM Billings, MT Chicago, IL Portland, OR Council Bluffs, IA
TRANSTAR SPONSORED ATSG SEMINARS 5/6/06 5/20/06 8/12/06 8/26/06
Atlanta, GA Phoenix, AZ St. Louis, MO Cleveland, OH
2006 SHOWS/CONVENTIONS: ATRA POWERTRAIN EXPO 2006 AAPEX SHOW
10/5/06 - 10/8/06 10/31/06 - 11/3/06
Sponored by ATRA & Gears Magazine Sponsored by AAPEX & MEMA
Orlando, FL Las Vegas, NV
8 CONTACT YOUR TRANSTAR REPRESENTATIVE FOR MORE INFORMATION!
MAIN OFFICE & INTERNATIONAL DIVISION 7350 Young Drive, Cleveland, Ohio 44146 U.S.A. Toll Free: 800-359-3339 Telephone: 440-232-5100 Cleveland Sales Fax: 440-232-0632 Web: www.transtarindustries.com E-mail:
[email protected]
TRANS
MISSIONS
IN THIS ISSUE:
Atlanta, GA 800-241-8524 Anaheim, CA 800-231-9000 Baltimore, MD 800-878-4249 Birmingham, AL 800-322-1026 Boston Area 800-446-9888 Chicago, IL 800-214-8710
Cincinnati, OH 800-543-2723 Cleveland, OH 800-321-8830 Dallas, TX 800-527-4821 Denver, CO 800-525-9096 Detroit, MI 800-356-1590 East Brunswick, NJ 800-654-3442
Ft. Lauderdale, FL 866-795-6666 Houston, TX 800-882-8844 Long Island, NY 800-445-1170 Minneapolis, MN 800-214-8710 New Orleans, LA 800-525-2512 Philadelphia, PA 866-750-8860
Phoenix, AZ 800-835-1234 Portland, OR 800-345-7500 Sacramento, CA 800-446-2600 SanFrancisco,CA 800-991-0117 Sarasota, FL 800-899-9623 Seattle, WA 866-254-1198
BULK RATE U.S. POSTAGE
We’ve created this newsletter for customers and friends of Transtar Industries, Inc. We encourage you to send or e-mail us your comments! Thank you.
SPRING 2006 VOL. 7 ISSUE 1
St. Louis, MO 800-446-7171 Spokane, WA 800-876-2292 Van Nuys, CA 800-231-9000 Bayamon, PR 800-981-3332 Toronto, Canada 888-869-0272
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SPX Filtran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 American Express Promotion . . . . . . . . . . . . . . . . .
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Got Gears - by Mike Riley . . . . . . . . . . . . . . . . . . . . 4 Why? - by Dave Hritsko . . . . . . . . . . . . . . . . . . . . . 6 New Parts & Products . . . . . . . . . . . . . . . . . . . . . . 7 2006 Seminar Schedule . . . . . . . . . . . . . . . . . . . . 7 Printed in U.S.A. — 2006 Transtar Industries, Inc., 7350 Young Drive, Cleveland, OH 44146 USA. All rights reserved.
Transtar agrees to sponsor 2006 ATRA Powertrain Industry Reception Transtar Industries is pleased to announce that we have agreed to sponsor the 2006 ATRA Powertrain Industry Reception at 7:00 on Friday, October 6, 2006 at Disney’s Coronado Springs Resort in Orlando, FL. “Transtar supports the educational efforts of ATRA to help shop owners and rebuilders have the most up to date information, “stated Tom O’Laughlin Vice President of Sales and Marketing for Transtar. “The Transtar Powertrain Reception is one of the ways we faciliate the sharing of knowledge between transmission shops, suppliers, and manufacturers in a relaxed setting.” Mark your calendars and plan to join us in Orlando for another great event. 2005 Powertrain Expo attendees enjoy hors d'oeuvres, drinks, entertainment and networking during the Friday night opening reception sponsored by Transtar Industries.
