May/June 2011

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TM

FOR THE TRANSMISSION REBUILDING INDUSTRY 

Hybrid Hybri d Electrical El ectrical Sa Safety: fety: Because Your Life May Depend on It!

A Look at the New MP Transfer Case

MAY/JUNE 2011

 

Increases in Line Pressure

 

EARS G

TABLE OF CONTENTS

FOR THE TRANSMISSION REBUILDING INDUSTRY 

MAY/JUNE 2011 PHONE (805) (805) 604-2000 FAX (805) 604-2006

         

Chief Executive Officer Dennis Madden Managing Editor   Rodger Bland Technical Director Lance Wiggins Advertising Frank Pasley Senior Designer    Jeanette  Jeanet te Troub

   

Contributing Editors:  Editors:  Carl Mustari Thom Tschetter 

 A Look at the New MP Transfer Case Page 34

Steve Bodofsky David Skora

ATRA Technical Staff:  Staff:  Mike Brown Pete Huscher Mike Souza

Bill Brayton Steve Garrett Randallll Schroeder  Randa

Director of Membership & IT Svc   Kelly Hilmer   Seminars & Convention Manager   Vanessa Velasquez Seminars   Bookstore Manager   Shaun Velasquez

 



 by Carl Mustari 

   

Hybrid Electrical Safety: Because Your Life May Depend on It!



  14 14   

When Electricity Goes Bad

  18 18      22

 by David Skora

Sticking Thermal Element Can Cause Thermal Failure

 The views expressed in this publication should not necessarily be interpreted as the official policy of the Automatic Transm Transmission ission Rebuilders Association (ATRA). Publication of product information or any advertising does not imply recommendation by ATRA.

Sticking Thermal Element Can Cause Thermal Failure Page 14

SPECIAL INTEREST & INTEREST & TECHNICAL

       

Hybrid Electrical Safety: Because Your Life May Depend on It! Page 4

 by Mike Souza

TRANSTAR, The Mission Possible Force TECHNICALLY SPEAKING: Allison... is that you?

 by Lance Wiggins

    30 30   

Don t Be Undon Undone e By Your To-Do To-Do List

 by Thom Tschetter 

, a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030, is published for the betterment of the transmission industry and is distributed nine times per year. No part of this issue may be reproduced without prior written permission of the publisher. GEARS  is distributed to members of the transmission industry in the United States, Canada, ATRA Members in Mexico & Europe, and related automotive industry firms and individually. Send changes of address to GEARS in care of ATRA. Subscriptions are available by contacting GEARS in care of ATRA.

 

 Advertisers and advertising agencies assume assume full liability for all content of advertisements printed and also assume full responsibility for any claims arising therefrom against the publisher. The publisher reserves the unqualified right to reject any advertising copy as it deems appropriate, with or without cause.

  62 62   

Sometimes a Rebuild Isn t the Only Answer

  64 64   

KEEP THOSE TRANNY S ROLLING: A Lincoln with an Attitude

GEARS ™

GEARS is

designed to provide accurate and authoritative information in regard to the subject matter covered. It is distributed with the understanding the publisher is not engaged in rendering legal, accounting or other professional service. If legal advice or other expert assistance, is required, the services of a competent professional person should be sought from a Declaration of Principles Principles jointly adopted adopted by a Committee of the American Bar Association and Committee of Publishers. GEARS also welcomes articles submitted by members of the industry. GEARS  considers all articles for publication that contribute positively to the welfare of the transmission industry, and reserves the right to edit all articles it publishes. If you would like to submit an article to GEARS, include background information about the author and a telephone number where he/she may be reached. If you want submissions returned, enclose a self-addressed, stamped envelope.

Editorial and Business Offices

  34   41 41      58

ATRA's Powertrain EXPO 2011, Las Vegas, NV FROM THE TECH DIRECTOR: It s All About Communication

 by Lance Wiggins

 

  69 

MEMBERSHIP MATTERS: You Made the Call and ATRA Answered

  70 

ATRA NEWS: Rapid R apid Transmissions Gets Its Party On! .

i C

C

C

C

DEPARTMENTS  



FROM THE CEO: Two Two Years Later A Recipe For Success

 

 by Dennis Madden

  72 72   

Powertrain Industry News

  77 77   

Shoppers and Classified

Fax (805) 604-2006

  84 84   

List of Advertisers

Publications Mail Agreement No. 40031403 Return Undeliverable Canadian Addresses to: Station A, PO Box 54, Windsor, ON N9A 6J5 Email: [email protected]

 by Steve Bodofsky 

 by Pete Huscher 

2400 Latigo Avenue, Oxnard CA 93030 Phone (805) 604-2000

 ww w. ge ar sm ag az in ine. e.co co m  ww w. at ra .c om

 by Steve Garrett 

A Look at the New MP Transfer Case

On the Cover: TRANSTAR  The Mission Possible Force Be Sure to Read The Feature story on page 18. it

(Paid Advertisement)

Issue #157

Printed in U.S.A.

Copyright ATRA 2011

 

FROM THE THE CEO  CEO

Two Years Later… A Recipe For Success

bymembers.atra.com Dennis Madden www.atra.com

wo years ago, in the April 2009 edition of GEARS Magazine, Magazine, we discussed the collapse of the automotive retail industry and the impact it would have on the transmission repair business. Back then, roughly 3000 dealerships across the country were expected to close. And once they had, we still couldn’t be sure if the industry had hit rock bottom and

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the auto repair business. But it came at a cost: the apathy of thinking that things were back to “normal”… that we could return to business as usual. It’s not. What you’re seeing, for the most part, is a huge hump in the cyclical nature of business. For the past two years we’ve been enjoying the side effects of the economic downturn, as  people were forced to cut back on luxu-

ties, were far more successful than those who relied on traditional marketing strategies. It wasn’t complicated: People were looking for a shop they could trust. Traditional marketing focuses on  sales;; community-based marketing is  sales about  people  people.. It’s about you and who you are. It gives potential customers an opportunity to connect with you and helps you develop a level of trust with them. So how can you take advantage of community-based marketing? It’s actually not all that complicated. There are no special tricks or secret handshakes. The easiest way to begin is to put yourself out there and get involved. Start by joining your local chamber of commerce or businesspersons association. And don’t just pay the dues: Attend the meetings. Volunteer your services. Whether it’s putting up holiday lights or serving pancakes at the annual pancake breakfast, every person

was on its way to recovery. On top of that, people were genuinely panicked over the shape of the economy and how it would impact their lives and their businesses. People weren’t buying new cars, but they weren’t fixing their broken cars either; we started to see a  glut  of   of broken cars  parked in people’s people’s driveways. As bad as things were, it seemed  pretty clear that, at some point, people would be less apprehensive about having their cars fixed, and we’d see a rush of repairs headed to transmission shops

ries, such as new cars. So, two years later we’re beginning to see a recovery in new car sales. According to Automotive News (www. automotivenews.com), the 1st  quarter of 2011 saw an increase of 13.6% in new car sales in North America as com pared to 2010. This followed a similar increase over the previous year. What does that mean to you? If you haven’t been working on those community marketing programs we’ve talked about over the last few years, it’s time to get started.

you meet is one more contact for you… and your business. Right now shops are still busy, and ATRA is working hard to keep them  busy.. But it starts with you: the shop  busy owner. It’s about becoming involved with your community and building on a reputation of trust… becoming the go-to guy (or gal) when the chips are down. It’s about being their “friend in the business” when they’re in need of your services. We’ve been working to improve ATRA’s reputation and name recogni-

across thethat’s country. And exactly what happened. Over the last year or two, people who would otherwise have bought new cars were spending their money to have their cars fixed. This was a fantastic boost to

During the economic bustreach we learned that business owners who out to their community, in the form of public service, press releases, car care clinics (last month was National Car Care month), and similar activi-

tion. That along with your effort to  build trust among the people in your community is a recipe for success.

2

GEARS May/June 2011

 

Hybrid Electrical Safety:

Because Your Life May Depend on It!

by Carl Mustari

The American Society for Testing and Materials has evolved into ASTM International. Its standards and ratings have been adopted for electrically insulated gloves. Vehicle manufacturers commonly recommend gloves with ASTM International’s Class 0 rating for work on hybrid vehicle high voltage circuits. This class 0 rating is the minimum required protection (1000V) for working on hybrids. OSHA requirements specify that high voltage gloves be inspected every six months by a qualified glove inspection laboratory. Some dealerships also rope off the vehicle being serviced to keep anyone else from entering the work bay during maintenance on hybrid cars. Once you’ve prepared to service the vehicle, you’re ready to approach the high voltage disconnect switch:

 

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hen working on any hybrid vehicle, safety is of utmost importance. You need to be aware of the high voltage and take the necessary precautions.

each use for any defects, such as small holes or tears. You should also wear leather gloves over the rubber gloves, to protect the rubber gloves from punctures (figure 1)

Before attempting any major repair work, make sure you’ve been trained in electrical hybrid vehicle safety, whether from a local college, tech school, dealership, or I-car safety classes. While working on these systems you should always wear class-zero rub ber gloves rated to at least 1000 volts. Inspect those gloves completel completely y before

You’ll need to wear these gloves until you’ve verified the hybrid system voltage is low or completely disabled. When not in use, it’s a good idea to store the gloves in a canvas bag with a ventilation hole in the bottom.

Figure 1

.







Rotate the switch from the lock  position to the unlock position. Pull the switch out and reset it to the shipping position (Ford Escape Hybrid example). Wait 60 seconds to allow the t he capacitors in the inverter to discharge. These capacitors can be rated

Figure 2

Figure 3

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GEARS May/June 2011

 

Whatever It Takes Does!!!    507 777 Front Cover Plate 0

 

861

 

140

 

778

Stator 

Input Clutch Hub

Pump Parts

 

Body  110

891

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571

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883 482

558

052

Underdrive Hub

 

O.Dr. Hub

 

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Reaction Planet

 

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Reverse Planet

760

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Input Ring Gear 

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235* 616 235*  616 241  241 

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Reverse Clutch

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Input Clutch Retainer 

O.Dr. / Reverse Piston

770

781 074

1-800-940-0197 • www.wittrans.com 950

w / Reverse Housing 995-2

Park Gear 

926B

M304317B

761 Case Parts

Ext. Housing

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342

 

Hybrid Electrical Safety

around 450 volts and 125 amps each. There are three capacitors in the inverter. All high-voltage checkpoints must  be tested with a Category III voltmeter rated at 1000 volts to verify the voltage has dissipated (figure 2).  Never assume there’ there’ss no voltage in the system; always check with a knowngood Category III meter. Remember: even when the system is discharged, the 300-volt battery pack can provide lethal voltages.

Hybrid Battery Information Hybrid batteries consist of 250 individual cells, similar in shape to a size D ashlight battery. Each individual battery cell is contained in a stainless steel case. Safety glasses must always be worn (gure 3). Each individual cell can create 1.3 volts. The cells are welded and wrapped together in groups of ve to form a module. There are 50 modules in the battery pack. The total battery pack voltage potential is 300 volts DC. The batteries are Ni-MH (NickelMetal Hydride). The battery pack contains sealed batteries similar to the  batteries used in radio controlled toys, laptop computers, and cell phones. The battery case is designed to be water resistant. The battery cells contain a base electrolyte — consisting of potassium hydroxide as the dominant active ingredient —absorbed in a special paper. The electrolyte won’t leak from the battery under most conditions; however, if the battery is crushed, it’s possible for small amounts of electrolyte to leak. If a wrecked hybrid vehicle comes into your shop, the vehicle’s safety systems should head off any potential safety issues. For example:

Figure 4

1.

The high voltage disconnect switch (previously discussed) should have disconnected automatically. 2. Manufacture Manufacturers rs locate locate the battery  pack where it’ it’ss least likely to be damaged: between the frame rails, ahead of the rear axle. 3. When the airbag deploys, it immediately cuts off power to the battery  pack. Most emergency medical technicians (EMTs) have received training in how to deal with this. Basic steps for disabling the HV system include: 1. Make sure the ignition was turned off and the key removed. This is important because a full hybrid runs on its silent electric motor when stopped and may appear to be turned off. Backup options include removing the IGCT relay or the HV fuse under the hood. 2. Disconnect the 12-volt battery. 3. Wear 1000-vol 1000-volt, t, Class 0-rated insulated rubber gloves and follow any special instructions provided in the service manual for disabling the high voltage system (figure 4). Procedures may vary between vehicles and may include removing a service plug or removing a locking tab and flipping a switch. 4. Check orange cables for any current using a CAT III certified digital volt-ohmmeter (DVOM) (figure 5).

Moving Hybrids in Service Bays The technicians shown (figure 6) have the hybrid vehicle on dollies to avoid charging the condensers in the inverter while pushing the car in and out of a service bay.

Figure 5

Submersion If a hybrid vehicle was fully or  partially submerge submerged, d, disable the high voltage battery pack, SRS airbags, and gasoline fuel pump. When putting a hybrid vehicle  back into service, check the insulation  before activatin activating g high voltage circuits. You can use an insulation tester, often called a megaohmmeter, such as the Fluke 1587, to test the insulation. Acceptable resistance ratings should be over 1 million ohms. If insulation resistance is less than one million ohms, you’ll need to locate where insulation may be weak.

Hoisting a Hybrid When hoisting or using a floor  jack, pay attention to the lift points. Orange cables run under the vehicle  just inside the frame rails on most hybrids.

HybridLevel cars areLegislation quiet; so quiet you Sound may not realize the vehicle is moving  because you can’t hear anything. anything. The federal government and a handful of states are considering legislation to set minimum sound levels for hybrid cars. In April, Representat Representatives ives Edolphus Towns (D-NY) and Cliff Stearns (R-FL) introduced the Pedestrian Safety Enhancement Act of 2008. The  bill proposes a two-year study to determine the best strategy for tackling safety concerns about hybrids among the visually impaired. Thanks to Cherokee Ford in Woodstock, GA for information on the 2011 Ford Fusion Hybrid.

Figure 6

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GEARS May/June 2011

 

 When Electricity Goes Bad by DavidDirector, Skora Technical Valve Body Pro

Sometimes isolating an electrical problem is as simple as just  looking around.

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his article is about how important it is to troubleshoot the electrical devices used to shift today’s transmissions correctly. Now, don’t stop reading just because I mentioned electricity: We’re not going to talk about Ohm’s Law or try to get you to use fancy meters or oscilloscopes. There are plenty of magazine articles and textbooks that already cover this subject very well. What I notice is that a lot of guys who are new to this industry don’t start to learn about electricity until they run into a problem. I can’t blame them: “If it ain’t broke, don’t fix it.” But, in reality, the best time to learn about electrical circuits is by testing cir-

off electrical circuit. Remember: these types of circuits involve a load device such as a light bulb, a fan, or a transmission solenoid. And they typically include a power source, a switch, and a ground, which make the device work. The textbook examples for a bad circuit include several scenarios such as an open or a short in the circuit or a continuity problem. In the real world,

Let’s take a look at a few examples and you’ll see what I mean: A general repair shop next door had a customer with 1996 E250 van equipped with handicap lift and modified driver controls (figure 1). I noticed that the tech had been working on this van for a few days. One day after work he told me the story. The issue was that it wouldn’t pass the smog test because

cuits that aresupposed good. That you know how they’re to way work. The following examples that I’ve come across may help guide your own troubleshooting… when electricity goes bad.  bad.  Let’s take a look at the basic, on-

it usually comes downthere’s to theno device or on-off switch is bad, power, or no ground. And while you could spend a lot of time and effort tracking down the specific problem, very often it’s not necessary.

the check engine lightright wasdirection: on. He started in the He

Figure 1: Interior of handicapped driver’s van.

recorded and cleared the code. During a test drive, he noticed that it drove fine until the check engine light came on; then it started shifting hard. He found

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GEARS May/June 2011

 

When Electricity Goes Bad

the same VSS code in memory. He then verified that the battery, grounds, and fuses were all okay. He also found out from the customer that the dash and  parking lights didn’t always always work. At this point he pulled the dash to check the circuits at the PSOM (Programmable Speedometer Odometer Module). Since the power and ground circuits checked out, he assumed the

from under the dash. The first thing I did was check for  battery voltage from fuse number 5 to the headlight switch. With the ignition off there was no voltage. When the ignition switch was on, there was only 8 volts. I think this is what had him confused. Clearly, a battery battery   fuse circuit should always always   have voltage, whether

the ignition is on or off. To be sure, I got similar results when I checked for voltage at the fuse side of the brake switch. Since he said he checked the fuse, I was getting suspicious of an open  between the fuse and the circuits it fed. So I pulled out the number 5 fuse: Lo and behold, there was a broken terminal on the feed side of the fuse (figure 2).

PSOM must be bad. He installed a used dash from a salvage yard. The owner  picked up the van and and returned the next next day with the same problem. The tech told me that the problem was erratic and seemed to be related to driving with the lights on. Sure enough, the wiring diagrams seemed to indicate a possible relationship between a common “joined in electrical lingo” voltage feed to the PSOM and the headlight switch. So at this point he installed a new headlight switch and new turn signal switch, and was consider-I ing ordering a newseriously dash assembly. couldn’t help but feel compelled to help him — not just for his sake, but also because I wanted to see the handicapped owner get his van back. The wiring diagrams showed a relationship between fuse number 1 and fuse number 5 in the dash panel fusebox. Number one provided the battery feed to the PSOM, brake switch, turn signal switch, and ABS module. Fuse number 5 was

Figure 2: A broken terminal on the fuse feed side misled troubleshooting.

an ignition feed to the transmission range sensor, turn signal switch, OD cancel switch, daytime running light module, and some other circuits. He decided that one of the switches was shorted, which caused a voltage drop before the PSOM. “WOW,” I said, “that’s amazing.” “Yeah,” he replied, “it would be, if I could find what’s doing it.” I offered to help him for a few minutes. He’d  been showing me the wiring diagrams to support his theory. I noticed the Figure 3: Is this or isn’t this a real 1996 Volkswagen 2.0L engine?

headlight switch hanging

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GEARS May/June 2011

 

When Electricity Goes Bad

Unless a code sets for one of the sensors, a lot of techs seem to ignore the potential problems a bad sensor can create. He’d probed the fuse test sockets on top of the fuse and it tested good, and he hasn't seen the van back again. This next example involves a look at a 2000 VW Jetta that occasionally set a VAG 00652 slip code. The owner was told by the first shop that he needed a transmission  because it was setting a slip code. The vehicle owner was skeptical: He wanted a second opinion from another

come across. I was asked by a friend of a friend (always a bad sign) to fix

forced the fuel pump relay to work all the time. It should have taken only a

transmission shop.me The of the second shop told theowner transmission worked perfectly until the computer system went into limp mode. As soon as they cleared the slip code, the transmission would drive and shift great. These symptoms didn’t seem to indicate the transmission needed to be rebuilt. Even though the TCM hadn’t set any other codes, we did a wiggle test on the OSS (Output Speed Sensor). All of a sudden an OSS code set. A new OSS fixed the problem, and it cost a lot less than a complete transmission rebuild. Remember, just because there’s no a trouble code doesn’t mean electricity can’t go bad. Let’s take a short review of com puter related troubleshooting: For a computer to control a transmission, it needs sensors to monitor the physical conditions the vehicle is under at every moment. Unless a code sets for one of the sensors, a lot of techs seem to ignore the potential problems a bad sensor can create. Remember, the speed sensors, temperature sensors, pressure sen-

amode. 1996The VWcomplaint that seemed to be like in limp sounded the transmission only drove forward in high gear and would back up okay in reverse. An initial check revealed several engine codes. It was hard to believe the engine would even start and run. Someone had wired the fuel pump to run all the time; otherwise the engine wouldn’t even start. Since the engine was able to run, his concern was getting the transmission to shift. As the story unfolded and I spent several hours diagnosing, troubleshooting, and testing circuits, I concluded that this was going to take a lot more time, money, and parts to fix than it was probably worth. Here’s why: The previous owner had replaced the engine with a used one (figure 3). My friend’s friend bought it this way and assumed some minor thing was causing the transmission not to shift right. The engine and transmission looked like they were all there and seemed to have the wiring connected to the usual sensors. In most typical situa-

few minutes to verify the were ECMgood. fuel  pump relay control circuits At first I wasn’t too concerned that none of the wiring diagrams matched the car’s wiring. “No big deal,” I thought, “it’s a Volkswagen.” To my amazement, I couldn’t find any wiring diagrams from any model or year Volkswagen that matched this car! To make a long story short, we finally realized that the engine had come from a 1995 Volkswagen. A few of the sensors (TPS, IAC, Idle Switch, wiring, etc.) were different between a 1995 and a 1996 VW. Since the 18-pin engine harness plugged right in the main wiring harness near the distributor (figure 4), both friends assumed it was going to work. It’s been over a year and, I as far as I know, the owner still hasn’t decided what to do. I hope these examples help illustrate that when it seems electricity has gone bad, fixing the problem may not require advanced diagnostic strategies. Sometimes you can make it right by using simple logic and knowing what it takes to make it good.

sors, engine load sensors, driver inputs (Tiptronics), and more supply vital information for the computer to control shift timing and shift feel. This final example illustrates what

tions with multiple codes, the logic is to solve the circuits which are setting the lowest number code first. One of the lowest codes present related to the ECM power circuits.

Figure 4: View of the 18-pin engine connector just below the radiator hose clamp.

sort of extreme situations you may

This made sense, because someone had

12

GEARS May/June 2011

 

A higher level.

That’s what you get with Ford gas engines and transmissions.  A higher build level means you’re getting engine and transmission assemblies built to the exacting specifications specificati ons of Ford Motor Company. So you not only get the quality build you expect in an assembly from Ford, but also one that’s built by using parts that keep it specific to year, make and model as well as emissions calibrations.

Introducing the all-new 3-Year Unlimited-Mile Warranty – No N o Commercial Exceptions Ford gasoline engines and transmissions are covered by a three-year/unlimited-mile warranty.* All warranties are backed by Ford Motor Company. They’re also supported by more than 3,500 Ford and Lincoln Mercury Dealerships nationwide as well as at their originating place of service. Plus, unlike some competitors, the warranty is good for fleet vehicles. That means you get the same advantages and coverage for commercial use, no exceptions. For technical questions, contact the Powertrain Assistance Center at 1-800-392-7946 or visit FordParts.com. *See dealer for limited-warranty details. Remanufactured diesel engines are covered by a two-year/unlimited-mileage warranty.

 

S t i c k i n g 

Thermal Element 

Can Cause Failure   4R / 5R55EThermal / 5R55W / S/N

by Mike Souza members.atra.com www.atra.com

Cooler Bypass System  ord’s 4R/5R55E and 5R55N/ W/S transmissions use a hydraulic cooler bypass system that can cause a system meltdown if the thermal element or fluid cooler bypass sleeve sticks.

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the overdrive planetary assembly com pletely destroyed. destroyed. Blocking the thermal valve sleeve in the stroked position will prevent this from happening. Some aftermarket companies supply a block to keep

This same problem may also cause intermittent lockup code P0741. The accompanying hydraulic diagrams show the function of the thermal element and sleeve: Figure 1 shows the thermal valve

If the sleeve part way it’ll restrict cooler flowsticks and cause internal component damage; meanwhile it may not set any fluid temperature codes. Very often the fluid will be burnt and

the fluidtemperature cooler bypass strokedAnother in the normal position. way to accomplish this is to move the return spring to the opposite side of the sleeve.

at rest (4/5R55E; orange) in position, the cold temperature position. In this the valve directs oil through the fluid cooler bypass sleeve (green), which allows the oil to flow to the cooler

Figure 1

Figure 2

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GEARS May/June 2011

 

Figure 3

Figure 4

Figure 5

Figure 6

GEARS May/June 2011

15

 

Sticking Thermal Element Can Cause Thermal Failure

through both cooler lines at the same time. Since there’s no return, there’s no cooler flow. This helps the transmission reach normal temperature faster in colder climates. Figure 2 shows the transmission at normal temperature: The thermal element moves the fluid cooler bypass sleeve (extended pin), blocking off the oil being applied to the upper cooler line fitting. In this position, oil flows to the cooler through the lower cooler line and returns through the upper cooler line. Figure 2 shows the lockup converter flow in the released position at normal temperature. Figure 3 again shows oil flow to the cooler at normal temperature, but with the lockup converter flow in the applied temperature,  position. If the sleeve gets stuck — completel completely y or part way  — it can restrict cooler flow in the converter clutch release  pressure circuit. This This can set DTC P0741. Placing the cooler bypass sleeve spring on the opposite side of the sleeve locks the sleeve in the normal temperature  position, preventing preventing a cooler flow problem. The diagrams for the 5R55W/S (figures 4, 5, and 6) and the 5R55N transmission (figures 7, 8, and 9) show cooler flow working the same way. The only difference is the thermal element, fluid cooler bypass sleeve, and converter clutch control valve lineup aren’t in the same bore. But blocking the fluid cooler bypass sleeve in the normal temperature such as bystill relocating spring to the opposite sideposition, of the sleeve, will keep thethe cooler flowing  properly and prevent overheating overheating problems. Figure 7

Figure 8

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Figure 9

GEARS May/June 2011

 

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GEARS May/June 2011

GEARS May/June 2011  

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20  

GEARS May/June 2011

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Which Is More Important: How It Works or What’s Wrong With It?

TECHNICALLY SPEAKING

Allison… I

  is tha thatt you?

t’s Monday morning and as you’re walking up to your bay you see a late model GMC sitting there. “There’s an Allison transmission in that truck,” you might say to yourself. Then the question: “I wonder what’s wrong with it?” You find out later the com plaint is no power. Before the test drive you perform a quick inspection, check for codes, and

make sure the vehicle is ready to drive. It has multiple codes; you record them and clear them from memory. During the test drive the vehicle goes in limp mode. Back at the shop, five minutes later, you find the wiring harness  pinched (figure 1). Two hours later the vehicle is fixed. Quick fixes like these are always great to learn about in seminars and training classes. But understandin understanding g how the transmission operates — and why the quick fix worked in the first place  — is just as important. But sometimes this transmission can fool you, like give you a false Neutral. Let’s take a look at how and why the Allison goes into fails and what causes it.

Understanding a False Neutral If power is interrupted while the transmission is operating in reverse or neutral, the transmission defaults to or continues neutral operation. At that point you can turn the engine off and start it again: The shift selector will provide reverse, neutral, and drive capability regardless of the range it was in when the failure occurred. In this state, pressure control solenoid 1 — PCS1 or trim A solenoid — is de-energized, and allows the 3rd, 5th and reverse clutches to apply. If you

Figure 1

bymembers.atra.com Lance Wiggins www.atra.com

move the selector valve into reverse,

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Figure 2

GEARS May/June 2011

 

Which Is More Important: How It Works or What’s Wrong With It?

Figure 3

main pressure is routed to the low and reverse clutch, allowing reverse operation. If you move the selector valve to drive, main pressure is routed to the 1-2-3-4 clutch, allowing 3rd gear operation. If the unit has no forward or reverse, or won’t move at all, follow these steps: Set the parking brake. Key off. Disconnect the case connector • • •







at the transmission. Using a fused jumper wire, connect terminal R (black/white) of the automatic transmission 20-way connector to a known good ground. Start the engine and move the range selector to reverse — the transmission should engage reverse. Move the range selector to drive — the transmission should engage 3rd gear.

Figure 4

Checking the Press Pressure ure for Diagnostic Purposes

Erratic Operation after Repair

shift sequences. If the shift timing  between two gears isn’t met, the TCM will attempt to adapt the timing of that shift within the program specifications. specifications. The vehicle will need to be driven more, specifically performing that shift. Many times this will correct the condition. It’s possible to reset individual shifts without affecting the other shifts. Monitor the adaptive cells on the scan tool to determine if the adaptive strategies have been met. Always reset the TCM to base cali bration and and fast adapt adapt for all all shifts. This can be done in one step with fast learn.

If you’re experiencing erratic transmission operation after a rebuild or a battery disconnect, it’s important to verify in which particular gears the erratic operation is occurring.

If you miss this step, the TCM adaptive values will be at their previous settings, set to slow adaptive mode. Under these conditions, it’ll take an unacceptably long time for the adaptive values to

normal operating temperatures 71-93ºC (160-200ºF). Start the engine. Check the transmission fluid level; adjust if necessary.

If reverse and 3rd gears are available in limp home mode, it may indicate an electrical failure. If only one or neither of the ranges work, it may indicate an internal hydraulic failure such as one of these conditions: Failed clutch Stuck valve Solenoid failure 1-2-3-4 clutch, 3rd, 5th and reverse clutch, and the low and reverse clutch • • • •

Checking mainline pressure helps determine if a transmission failure is due to a mechanical or an electrical condition (figure 2). Caution: Keep the brakes applied at all times to prevent unexpected vehicle motion. Personal injury may result if the vehicle moves unexpectedly. Engine off. Remove the oil pressure tap  plug. Install the oil pressure gauge. All transmission fluid level and  pressure checks must must be made at • •



• •

Use a scan tool to determine these

adjust for the new transmission.



Use the scan tool to check the

24

GEARS May/June 2011

 









• •



engine RPM. With the brakes applied, record the line pressure values with the engine at 600 RPM, in neutral and reverse. The transmission will be in converter mode: torque converter clutch not applied. With the brakes applied, record the line pressure values with the engine at 2100 RPM in neutral. The transmission will be in converter mode: torque converter clutch not applied. With the brakes applied, use your scan tool to check pressures in first through fifth gear ranges at 600 RPM. The transmission will  be in converter mode: torque converter clutch not applied. Compare the data recorded to the line pressure specifications (figures 3). Engine off. Disconnect the oil pressure gauge. Install the oil pressure tap plug.

Figure 5

Problems and Fixes We’ve covered the basics; now let’s cover the problems and fixes. Code P0842 (Transmission Fluid Pressure (TFP) Switch 1 Solenoid Circuit Low Voltage) Code P0847 (Transmission Fluid Pressure (TFP) Switch 2 Solenoid Circuit Low Voltage) DTC Code P0872 (Transmission Fluid Pressure (TFP) Switch 3 Solenoid Circuit Low Voltage)

These codes can be caused by a fault in a clutch circuit, the valve body, a shift solenoid, or a faulty pressure switch circuit. These codes may be hard faults or intermittent codes. To verify whether a shift solenoid, shift valve, or clutch is at fault, swap shift solenoids C, D and E with one another. If the problem remains the same, look for a valve or clutch fault. If it changes, suspect the solenoid. With the valve body removed, you can air check each clutch (figure 4).

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GEARS May/June 2011

25

 

Which Is More Important: How It Works or What’s Wrong With It?

Always service the spin-on oil filter at regular intervals. Make sure the magnet is present at the top of the filter. Always make sure the valve body  bolts are tightened evenly to 84-110 in-lbs. A burnishing tool is available through the aftermarket to smooth out any irregular marks in the bore for the E shift valve. If the E shift s hift valve sticks in its bore, it usually affects 4th gear and sets code P0872. After you clear the code, the vehicle will shift normally: 1-2-3. Gear ratio error in 5th (P0735 2001-2005), or 6th (P0736 2006-on)  before and after a rebuild rebuild can be caused  by a damaged range fork in the transfer transfer case, causing the transfer case to pop out of gear at freeway speeds (figures 5 and 6). Units affected are 2001-current K Series Chevy Silverado/GMC Sierra 2500HD/3500. Four wheel drive vehicles equipped with Allison transmissions transmissions use the vehicle speed sensor on the transfer case as an output speed sensor. When the transfer case goes into neutral, the computer sees the input RPM change as vehicle speed remains constant, so it thinks the transmission is slipping. One of the main causes for this failure is a lack of lubrication due to low fluid level. Over time, the pump assembly can wear a pinhole into the magnesium case and produce a small leak. GM has released an updated clip that resists wear from the pump into the case (figure 7). GM has also released an updated range fork and hub assembly to help with wear issues. Anaheim Anaheim Gear of Anaheim, California recommends using GM Autotrak fluid for improved durability. Autotrak Fluid P/N 12378508 Range Fork P/N 12544310 (261 XHD) 12384964 (263 XHD) • •

We’ve also found the snap ring groove in the rear case half for the output bearing is wearing out (figure 8). The magnesium case is too soft and the axial movement of the output shaft causes the snap ring groove to widen as much as 0.0200”. This excess clearance causes the entire shaft to walk  back and forth, resulting in range fork wear, which can cause the transmission to shift into neutral at freeway speeds.

Figure 6

Figure 7

Figure 8

26

GEARS May/June 2011

 

  ,  n   e    t t  g  f  n o   o  l o    s s    a a  y  s  r e  m o  E ve c    y  g o  l o  n  h   c  s e e    t t  g  ne w  h a n  t  co m p l  le e t  te eo l y    t y   c  s.  s .  g  h a t    n n  t h  i    h h   t    d d e    w w  y  a    w w e  h  t h

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Which Is More Important: How It Works or What’s Wrong With It?

LCT 1000 applications may exhibit late shifts, no shifts, or a lack of power. This may be caused by the PTO switch indicating that the PTO is being commanded on. It may act very similar to a  plugged fuel filter, and likely won’t set a DTC. The TCM is being commanded  by the ECM to change the shift points for the transmission. The engine speed will typically be limited to 2000-3000 RPM (depending on calibrati calibration). on). You can monitor the PTO switch with a scan tool on most applications. If the PTO switch is activated or if the switch has failed, the ECM will limit engine RPM at all throttle openings. In addition, you may notice that turbo  boost pressure, MAF, and fuel delivery commands indicate the engine isn’t under full load. When these conditions are met, the ECM will command the TCM to change the shift points, which can lead to the complaint. If the switch is

off, check the switch and wiring with your scan tool or multimeter. Repair or replace the switch as necessary. The PTO switch on the 2001-06 applications is located right of center on the dash (figure 9). Many customers are installing PTO switches in vehicles that weren’t originally equipped with a PTO from the factory. Customers are using the PTO input to force the engine to idle up to speed after the engine warm up. The factory harness is in place up to connector C106, so the installation is fairly simple. PTO switch kits are available from several sources. This means this condition may occur even though the vehicle isn’t equipped with a PTO. LCT 1000 applications may exhibit any of these conditions: Transmission won’t move forward or reverse (range inhibited). Possible electrically related •



shift solenoid, temperature sensor, or PSM DTCs. Transmission will move forward and reverse but won’t shift. These conditions may be intermit•

tent. Inspect the main transmission harness; it may be pinched where the frame rail meets the body (at the body mounts). If the harness is pinched, repair the wiring and reroute it to prevent it from becoming pinched again. This problem is common on crew cab applications. Vehicles come and go. Knowing what it takes to fix them is like having the key to every room: all you have to do is turn the key. Until next time, remember: Understanding how the transmission operates is just as important as understanding why it’s acting up.

Figure 9

28

GEARS May/June 2011

 

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Don’t Be Undone By Your “To-Do” List

by Thom Tschetter  members.atra.com www.atra.com

T

here are few things that bring as much pleasure or sense of accomplishment as crossing something off your “To-Do” list. It simply feels good to complete just about any task that was worthy of your list. In fact, it feels so good that it can  become addictive. addictive. Most successful people use a To-Do list in one form or another, and they wouldn’t consider giving it up. When you think about it, time management programs, day planners, and schedulers are little more than To-Do lists. Some are more sophisticated and include things like prioritizing, progress tracking, and so on, but in the final analysis they’re just a fancy way of keeping track of the things you have to do. As usual, I’m up to challenging traditions and questioning what we might call “conventional wisdom.” If you’ve ever seen the musical  Fiddler on the  Roof, you  Roof,  you know how deep-rooted traditions can block change. But regardless of how much we say we resist change, let’s face it: For the most part, change is good. In fact, we love change. We rearrange furniture, modify colors, buy new and improved products, update our wardrobes, get new cars, and yes, we even elect our leaders because they  promise change. A To-Do list is generally all about change; it’s a list of things you want to

quality of our lives. I’ve observed many shop owners who are so busy working on their To-Do lists that they don’t look up long enough to consider new ideas or opportunities, or to set time aside for setting goals and developing plans for accomplishing them. In short, marking things off their To-Do lists becomes their goal, and they get their sense of accomplishment from crossing the things off the list instead of improving their businesses. I believe there are some fundamental flaws in how we’ve traditionally used To-Do lists. The lists themselves

First, let’s assume that your To-Do list is only made up of things that are truly important enough to justify being on YOUR list. If you have no criteria for determining what deserves to be on YOUR list, add “create the criteria” to YOUR list right now. You should always consider whether something deserves to be on YOUR list. For many of you, this one step will shrink the size of YOUR list and make it easier to take the next steps.  Note the use of the word “YOUR” in the previous paragraph. Implicit in the word YOUR is the concept of ownership. These are tasks that you

fix or improve in your life. So how can a To-Do list block  change?   change? Many of us can become so focused on accomplishing what’s on our To-Do lists that we

can become so overwhelming that we resist anything new because it’ll result in adding to our already unmanageable lists. So let’s take a look at how we

own, or, in other words, only you can or should do. What about all the things that don’t meet the criteria to be on YOUR list,

miss out on opportunities to improve our businesses, our processes, and the

might improve things by changing how we use To-Do lists.

 but still need to get done? Chances are those things can go on a new list.

30

GEARS May/June 2011

 

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Don’t Be Undone By Your “To-Do” List

Let’s call the new list “Things to Delegate.” Again, if you haven’t created any criteria for determining what you can delegate, add that to YOUR list right now. We don’t have the time or space to deal completely with how to delegate effectively, but Theodore Roosevelt put it this way: “The best executive is the one who has enough sense to pick good  people to do what he wants done, and enough self-restraint to keep from meddling with them while they do it.” Here is a simple “…ATE”-step approach to help you delegate: StimulATE — Present what you want them to do and why to do it. EducATE — Explain how to do it. DemonstrATE — Show them how you want it done. SimulATE — Give them a chance to try to do it. •











EvaluATE — Provide feedback on how they did and correction as needed. CongratulATE — Because what gets rewarded gets repeated.

Many times, the things on the lists are game changers. Once completed and implemented, game changers fundamentally affect what is done or the way things are done. They often eliminate the need to continue doing certain things, as well as clearly illuminating the things that you need to  start   doing and the things you need to keep keep doing.  doing. This creates the need for another small group of lists: the Stop-Doing   list, the Start-Doing   list, and the  Keep-Doing   list. Here’s a simple example of how this all works together. Let’s assume you’ve decided to add brake repair to your menu of services in your transmission shop. Here’s how you might use these examples to manage the changes: Create a comprehensive list of all the things that need to be done to pre pare for and implement implement this new service  package. Examples Examples would include: • • • •

 purchase equipment equipment hire or train techs establish supplier relationship relationshipss adjust how you schedule

Determine which of the things on this list must be done by you and put them on YOUR To-Do list. Maybe

you most likely already guessed, his clean up guy continued to vacuum the cars and wash the windows.

you’re the only one to make the equipment purchases, but your manager will take care of the staffing needs. You might have the manager gather a list of  potential suppliers, but you’ll negotiate the pricing and terms. Determine who will do each of the remaining steps using the “…ATE”step delegation process. Decide what needs to go on the Start-Doing list. One example would  be to start inspecting brakes as part of every diagnostic service. Decide what goes on the KeepDoing list. For instance, you’ll need to keep using your established diagnostic and sales procedures to make sure your customers receive the same level of satisfaction as they’ve come to expect from you. Your Stop-Doing list will certainly include, “stop referring brake work to the brake specialist up the street.” While this seems to go without saying, don’t assume anything. I know a shop owner who always had one of his clean-up guys vacuum customers’ cars and clean the windows inside and out. When a new

The key point is that the traditional To-Do list can become both overwhelming and addictive, yielding unintended results and stunting creativity and innovation. But by applying some simple principles, you can manage the  process instead of doing it all yourself. And by the way, share some of those feelings of accomplishment with your team… they’ll enjoy crossing things off their lists, too. Thom Tschetter has served our industry for three decades as a management and sales educator. He owned a chain of award-winning auto centers in Washington State for over 25 years.  In 1996 his business was honored as the No. 1 small business in the state, and ranked in the top 10 nationally.  He also volunteers on the board of directors for the Auto Repair Good Guys Foundation, a non-profit foundation, which provides consumer education and guidance, charitable car repairs, and scholarships to automotive vo-techs in Arizona. Thom is always eager to help our industry. You can contact him by phone at (480) 773-3131 or e-mail to coach-

car wash opened up across the street, he decided to start having all the customers’ cars washed. The car wash did a great job, including vacu-

[email protected].

appointments   …and more.

uming the cars and cleaning all the windows inside and out. And, as

32

GEARS May/June 2011

 

New from BorgWarner!

Resistance is futile. New from BorgWarner: Part No. 50155 Replacement EPC Solenoid Fits Ford/Mazda transmissions 4R44E/4R55E/5R44E/5R55 4R44E/4R55E/5R44E/5R55E E Derived from a proven “force motor” design used in millions of transmissions, BorgWarner’s EPC replacement solenoid greatly reduces your risk of  stuck spool valve conditions associated with our  competitor’s “direct acting” design. The internal moving parts of BorgWarner’s solenoid core are made of hardened steel for incredible durability, and the hydraulic section is made of precision machined aluminum, anodized to resist wear and contamination, with a filtered inlet and outlet for  added protection.

BorgWarner carries a full line of ready to ship OEM BorgWarner quality clutch plates, transmission bands, one-way clutches, and electronic transmission solenoids that are 100% guaranteed to fit your rebuilds. BorgWarner Inc. Transmissio BorgWarner Transmissionn Systems 1350 N. Greenbriar Dr. Unit B Addison, Addiso n, IL 601 60101 01

Over time, normal transmission wear adds contaminates to transmission fluid, which may cause the spool valve movement of our competitor’s OE design to become sluggish and output pressures imprecise, resulting in poor shifts, slippage, and high line pressure problems. By contrast, BorgWarner’s larger internal spool valve is moved with hydraulic force, developing more than THREE TIMES THE FORCE of the OE design to plow through debris to meter oil flow properly. Calibrated to ensure smooth and durable operation, and verified by extensive field testing, BorgWarner’s EPC solenoid is the unbeatable choice for robust performance against transmission fluid contamination. Call your authorized distributor today and ask for  genuine OEM quality solenoids from the global leader in automatic transmission technology... BorgWarner, Inc.

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A Look at the New MP Transfer Case  by Steve Garrett members.atra.com www.atra.com

I

f you’ve had the opportunity to look under a new 4WD truck lately, you’ve probably noticed something new: The transfer case looks a little different than those you’ve  become used to working with for the last decade or so. Starting with the 2007 model year, General Motors introduced a series of new transfer case designs to replace

for years, but the internal operation of the shift mechanism is quite different. The MP units use a new design shift motor. In addition, this new design shift motor requires a learn process after replacement, for the control module to learn its position properly.

the New Venture Gear units they used in the past. Built by Magna Powertrain (MP), the new units are available in three different models: Manual Shift (RPO NQG; models 1222/1225/1226) Electric Shift (RPO NQF; models 1625/1626) Auto (RPO NQH; models 3023/3024) Several models are available for each application, including the 1222/1225 and 1226 manually shifted units, the 1625/1626 electrically electrically shifted units, and the 3023 and 3024 auto/ active transfer case models (figure 1). All models use DEXRON VI fluid. The models features are shown in the accompanying chart. (Chart 1) There are several differences  between the transfer cases beyond the control system. Some are minor while others will create major parts interchange problems if you try and install the incorrect parts for the unit you’re working on. To identify the transfer case, check the tag or stampings on the case (figure 2). As you can see from the chart, there

First we’ll look at how these units operate: (RPO NQF) MP 1625/MP 1626 (RPO NQH) MP 3023, MP3024 Like other electric shift GM transfer cases, the MP 1625 MP







are nine different transfer cases just for GM application applications. s. So what’s so different about these units? Well, in a nutshell, the construc-

MP T Case Operation

1626, MP 3023 and MP 3024 use these operational modes: 2 High 4 High Auto (MP 3023, MP 3024) 4 Low — 2.68:1  Neutral The MP series electronic transfer • • • • •





Figure 1

RPO

Trans

Input Shaft Splines

Output Shaft Splines

NQG

4L60E

27T

32T

NQG

6L80

32T

32T

NQG

6L90

29T

31T

MP 1226 Super Duty

NQG

6L90 LCT 1000

29T

31T

MP 1625 Heavy Duty

NQF

6L90

29T

MP 1626 Super Duty

NQF

6L90 LCT 1000

NQH

Model MP 1222 Light Duty MP 1222 Light Duty MP 1225 Heavy Duty

MP 3023 Light Duty MP 3023 Light Duty MP 3024 Heavy Duty

Chain Size

Planet

App

3 Pinion

½ Ton

3 Pinion

½ Ton

5 Pinion

¾ Ton

7/16– 1.5

5 Pinion

¾ Ton 1 Ton

31T

7/16– 1.5

5 Pinion

¾ Ton

29T

31T

7/16– 1.5

5 Pinion

¾ Ton 1 Ton

4L60E

27T

32T

3 Pinion

½ Ton

NQH

2ML70

32T

32T

3 Pinion

½ Ton

NQH

6L90

29T

31T

5 Pinion

¾ Ton

7/16– 1.25 7/16– 1.25 7/16– 1.5

7/16– 1.25 7/16– 1.25 7/16– 1.5

tion of the units is similar to the NV design transfer cases you’ve worked on

CHART 1

34

GEARS May/June 2011

 

Hard parts…need par ts…need one? Need 100? Can’t nd what you’re looking for?

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Based in Columbus, Ohio, G-Cor Automotive Corp. proudly houses the largest inventory of used automatic transmission hard parts in the USA! With W ith an organized processing center of 90,000 square feet, and 100,000 square feet of inventoried import and domestic hard parts, we’re condent we can meet  your need. Just ask!  When it comes to quality quality our parts speak for themselves. Our machine shop staff takes pride in their attention to detail. Our sales team is knowledgeable and experienced. And our service won’t be beat! • Huge selection of good used automatic transmission hard parts •  Warehouse Price and Private Label programs available • Rebuilder pricing for quality used hard parts • After-market and O.E.M. new hard parts • Export Sales Program available

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A Look at the New MP Transfer Case

Key on A/T shifter in neutral VSS less than 3 MPH (5 km/h) Move the switch into (or out of) the 4 Low position To select neutral position for towing purposes: Key on A/T shifter in neutral VSS less than 3 MPH (5 km/h) Transfer case in 2 High position Rotate the switch clockwise past the 4WD Low position and hold it in that position for 10 seconds. The red neutral lamp will light. • • •



• • •

Figure 2





Transfer Case Motor Lock  Transfer Case Control Module Vehicle Speed Sensor  Service 4X4 Indicator  Transfer Case Shift Control Switch The rotary switch (located in the dash) varies the voltage drop to the Transfer Case Control Module (TCCM)  based on the switch’ switch’ss position. The TCCM provides a 5-volt reference signal to the switch. As you rotate the switch, the resistance varies within the switch input circuit, creating different signal voltage values at the TCCM. The TCCM monitors the signal voltage to determine which range to select. Approximate TCCM voltage input will read: 2WD — 2 Volts Auto — 4.4 Volts 4 High — 3.0 Volts 4 Low — 1.5 Volts • • • • •

• •

Auto Transfer Case Operation (RPO MP 3023, NQH) MP3024 Figure 3

The MP 3023 and MP 3024 transfer cases include these components: Transfer Case Shift Control Switch Transfer Case 2WD, 4WD Incremental Sensor  Transfer Case Actuator Drive Motor  Transfer Case Shaft Position Sensor  •

cases are “shift on the fly” units. To select 2 High, Auto, or 4 High range, simply rotate the switch to the desired  position. The transfer case will only shift into or out of 4WD Low under these conditions:







• •

Transfer Case 2WD/4WD Incremental Sensor The incremental sensor is mounted on the transfer case shift motor. The sensor is a variable position, Hall Effect sensor that creates a signal the TCCM uses to determine the actual range position the motor is moving toward. The TCCM sends an 8-volt reference signal to the sensor (5-volt on Dodge applications). The sensor indicates the changing position for the

36

GEARS May/June 2011

 

* The motor direction will register CW while shifting up in range: 2WD to Auto to 4 High to 4 Low. Once the shift is completed, the motor  position will read CCW. CCW. ** The impulse voltage will vary based on sensor movement. It isn’t uncommon to have the voltage read 0.75V, then change to 4.2V; or the opposite may occur, depending on the exact  position of the motor motor.. In other words, when shifting the transfer case, you’ll see the value change without your input. This is due to the linkage varying  just a fraction of a degree degree or so from the last commanded shift into that range.

Figure 4

transfer case motor in degrees (0.15º increments) of movement. The sensor pulls the signal voltage low (0.75 volts), or allows it to go high (4.2 volts) as the motor rotates. Sensor operation can be confusing, because the transfer case position doesn’t necessarily represent a specific voltage value. You can monitor the sen-

Transfer Case Shaft Position Sensor (Rotational Sensor) The rotational sensor is mounted

sor voltage and degrees of movement with your scan tool. Typical values will  be (chart 2): Command

Incremental Sensor 

into the back of the transfer case near the

Incremental Incremental Incremental Incremental Sensor  Sensor  Sensor Voltage Sensor Impulse** Direction Direction

2WD

37º

0.75V

7.5V

Auto

102º

0.75V

7.5V

4 High

127º

0.75V

7.5V

4 Low

–77º

4.20V

7.5V

0.75V or 4.2V 0.75V or 4.2V 0.75V or 4.2V 0.75 or 4.2V

CCW CW* CW* CW

CHART 2

D O Y O U WA WA N T T O G E T I N T H E

HIGH PERFORMANCE REBUILDING BUSINESS??  BUSINESS?? 

motor assembly (figures 3 & 4). On some applications, the sensor may be described as the Transfer Case 2/4 Wheel Drive Actuator Position Sensor .  No matter the name, the operation is the same: The TCCM sends a 5-volt reference signal to the sensor. The TCCM also provides the ground for the sensor. As the shift shaft rotates, the sensor sends a signal voltage to the TCCM which varies with the position of the shaft. This value represents the actual  position of the shift shaft. Typical scan voltage values are (chart 3): Command

Sensor Degrees

Sensor Signal Voltage

2wd

37º

3.0V

Auto

102º

3.6V **

4 High

125º

4.0V

4 Low

-77º

1.8V

CHART 3

** Voltage varies with clutch command.

Transfer Case Motor The transfer case motor is a permanent magnet, PWM, bidirectional unit, currently manufactured by Bosch (Daewoo on 2011 applications; figure 5). The TCCM controls the drivers for the motor A and motor B circuits. The motor current varies depending on the command, and to meet the clutch slip requirementss in Auto Mode: requirement

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GEARS May/June 2011

37

 

A Look at the New MP Transfer Case

Figure 6

Figure 5

From 0-15 amps Current limited to 30 amps Motor resistance 14-20 ohms Unlike the previous design NVG transfer case motors, the new design • • •

actually rotates the shift shaft either clockwise (CW) or counterclockwise (CCW). This moves the actuator cam to apply or release the clutch. As the actuator cam rotates, the  balls located between the levers are forced up the ramps built into the levers. This forces the levers to move apart, applying pressure to the clutch. Increasing the clutch apply pressure reduces clutch slip, which, in turn, increases the torque applied to the front driveshaft (figures 6 and 7). After replacing the transfer case motor, you must perform a transfer case motor learn process with a scan tool.

Command

Motor Brake Voltage Feedback

2 WD

7.5 Volts

Auto

0.5 V **

4 High 4 Low

7.5 V 7.5 V CHART 4

tool isn’t available, you can use the vehicle’s electronics. You must perform the clutch relearn process after any of these situations: •

The transfer case was replaced. The TCCM was replaced or reprogrammed. The transfer case was rebuilt or internal repairs were performed. Clutch reset with with a  a scan tool: Key on, engine off. Access the Special Functions menu with your scan tool. Select Clutch Reset Procedure (Motor Learn Procedure). When the Clutch Reset Procedure is initiated, you should hear the motor engage, indicating a successful learn  procedure. Clutch reset without  a   a scan tool: Key set to accessory accessory.. Switch into the 2 High mode. Turn the switch clockwise past 4 Low into the neutral request mode and hold it for 30 seconds. •



on the commanded position. The 0.5 volts listed in the chart is based on the vehicle being stationary with no wheel slip. As the TCCM changes the clamp load, you may see the voltage change. The brake can cycle in as little as 20ms from fully locked to fully unlocked. This action balances the commanded  position for the motor with its actual  position, so the motor doesn’t need to stay energized all the time in Auto range.

• •





Transfer Case Motor Brake  NQH applications use a brake assembly to control the position of the transfer case motor armature. The  brake is mounted within the transfer case motor assembly, and is controlled electronically by the TCCM. The TCCM controls the ground for the brake assembly. The brake is deenergized (motor locked) during 2wd, 4 High and 4 Low ranges. In Auto range, the brake is energized (motor unlocked) if the motor requires movement. Typical scan values will read (chart 4):

Replacing and Reprogramming the TCCM Both the NQH and NQF transfer case applications will require programming if the TCCM is replaced or if an updated calibration is released. The  process is the same as for other GM modules and carries the same procedures and precautions as you’ve used in the past with GM modules.

NQH, Case ClutchNQF ResetTransfer Procedure One additional service area is the need for the TCCM to relearn the

• •

You should hear a noise from the motor, indicating a successful learn  procedure. As you can see, the new MP family of transfer cases isn’t something you should be afraid to tackle when one comes your way. Next time we’ll look at some of the common problems you may see with these new units. Until then, remember: The only limits are, as always, those of vision.

** The voltage (current flow) for the brake circuit will vary depending

38  

transfer case clutch. You can perform this process with a scan tool. If a scan

GEARS May/June 2011

   

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thursday, october 27 2:00pm - 6: 6:00pm Management Seminars 3:00pm - 6:00pm Technical Seminars 3:00pm - 6:00pm

Attendee Re Registratio ionn The Importance of Processes & Procedures in a Crisis - Martin Brooks (Christschurch, New Zealand)  Transformational Thinking - Dennis Madden & Rodger Bland (ATRA)  The Quick Fixes You Need Right Now - Lance Wiggins & Randall Schroeder (ATRA) 

friday, october 28 8:00am - 3: 3:00pm

Attendee Re Registratio ionn

8:00am - 9:00am

ATRA Member Meetin ing g

Management Seminars 9:00am - 12:00pm

Yes You Can!™ - Bob Cooper (Elite Worldwide, Inc) 

Technical Seminars 9:00am - 10:00am

A Shop’s Guide to Cost Savings, the Green & Safe Way - Carl Mustari (Chattahoochee Tech College)  Focusing on What You Need to Fix Transmissions TODAY - Dave Skora (Valve Body Pros) 

Technical Seminars 10:00am - 11:00am

CAN BUS: A Simplistic But Intuitive View - Bill Henney (Bluereach Automation & Control Ltd)  Street Smart - Mike Brown (ATRA) 

Technical Seminars 11:00am - 12:00pm

Diagnostic Breakdowns - Sean Boyle (Southern Illinois University)  Servicing & Repairing Chrysler Transmissions A to Z - Alan McAvory (Chrysler Midwest Business Center) 

Management Seminars 1:00pm - 5:00pm

Success or Struggle? You Decide! - Maylan Newton (ESi)  The Four Gears in Online Marketing - Danny Sanchez (Autoshop Solutions) 

Technical Seminars 1:00pm - 2:30pm

Electro-Hydraulic & Mechatronic Control - Bob Warnke (Sonnax)  LCT 1000 Problems & Updates - Steve Garrett (ATRA) 

Technical Seminars 2:45pm - 4:15pm

What Are You Doing to Reduce Comebacks? - Bill Brayton (ATRA)  Vital Voltage Drop Tests You Should Know - Dan Marinucci (Communique) 

Technical Seminars 4:30pm - 6:00pm

Is It The Torque Converter or the Transmission? - Joe - Joe Rivera (ProTorque)  Ford Powertrain-Fixing Powertrain-Fixing It Right the First Time - Stevie LaVallee (TEST Research) 

saturday, october 29 8:00am - 3: 3:00pm Management Seminars 9:00am - 12:00pm

Attendee Re Registratio ionn Creating a Customer...For Free! - Scott Harris (Mustang Marketing)  Step Into the Thinking Room - Coach Ron Tunic (CRT Broadcasting) 

Technical Seminars 9:00am - 10:30am

Real World Problems & Corrections - John -  John Parmenter (Precision International)  Hybrid Service & Repair for Transmission Techs - Jack - Jack Rosebro (Perfect Sky) 

Technical Seminars 10:30am - 12:00pm

4EAT, Phase II, 4AT or 5AT Which Is It? - Mike Souza (ATRA)  Chrysler CVT & Product Line Tests and Reviews - Randall Schroeder (ATRA) 

1:00pm - 2:00pm

ATRA Luncheon

2:00pm - 5:00pm

Trade Show

5:00pm - 7:00pm

Cocktail Receptio ionn

sunday, october 30 8:00am 0 0am - 10: 10:00am 0 0am

Supp Su pplilier er Mee Meetiting ng & 20 2012 12 Ex Exhi hibi bito torr Boot Boothh Draw Drawin ing g

9:00am - 2: 2:00pm

Attendee Re Registratio ionn

Management Seminars 9:00am - 12:00pm

Green Eggs & Ham Power Breakfast - Scott Johnson  Round Table Q&A - What’s Working Management Team 

Technical Seminars 9:00am - 10:30am

Supplier Showcase: Sonnax  Supplier Showcase: Auto Research Design 

Technical Seminars 10:30am - 12:00pm

Supplier Showcase: Mustang Dyno 

12:00pm - 5:00pm

Trade Show

monday, october 31 9:00am - 1: 1:00pm

Attendee Re Registratio ionn

 s   c  h    e  d    u  l     e  a 

 t   a   g  l    a  n   c   e 

9:00am - 2: 2:00pm

Trade Show

 

 

thursday | seminars

thursday october 27 2:00pm - 6:00pm Attendee Registration

3:00pm - 6:00pm Technical & Technical  & Management Management Seminars  Seminars

3:00pm - 6:00pm Management Seminars The Importance of Processe Processess and Procedures in a Crisis Martin Brooks (Christschurch, New Zealand) 

Last February, February, Martin’s two transmission shops were hit by a major earthquake. earthquake. He’ll explain how having well dened processes and procedures helped with a quick recovery while other businesses struggled. And, while you may never experience a major earthquake, you’ll see how having clear processes and procedures in place can be your lifeline during times of crisis.

Creating a Customer...For Free! Dennis Madden & Rodger Bland (ATRA)  ATRA’s ATRA ’s Dennis Madden and Rodger Bland will help you

Transformational Thinking:  A Look Back… A Look Ahead It’s been 5 years since we first started to examine what makes one shop successful while others struggle. Every step of the way added a new piece to the puzzle, until we got a clear view of the picture. The difference, it seems, is all in your head.  At this year’s Management Seminar Program, we’ll focus on  you. We’ll look at how you view  your business, and the need to transform your thought processes to redefine what it takes to build a successful transmission repair business.

examine the different ways that your thought processes can inuence your shop’s success or failure. You’ll see how transforming your thinking to alter your attitude toward your business can have a dramatic effect on how your customers view you and your shop. Most importantly, importantly, you’ll discover the value of building your customers’ trust, and how that trust can help eliminate the stumbling blocks that so many shops face when dealing with potential customers.

3:00pm - 6:00pm Technical Seminars The Quick Fixes to “Get the Customer Out the Door” Lance Wiggins & Randall Schroeder (ATRA)  The latest xes and quick tips to help you get the customer out the door as soon as you get back to the shop. This program will have the latest transmission failures and the repairs based on the past year of ATRA HotLine calls.

44

ATRA’s Powertrain Expo

 

 

seminars | friday

9:00am - 12:00pm

friday

Management Seminars Yes You Can!™ Bob Cooper (Elite Worldwide, Worldwide, Inc)  When it comes to building a more protable, successful shop, Bob Cooper says… “Yes you can!” He was one of the rst to predict vehicle leasing programs, the trend in auto maintenance, and the dealers aggressively a ggressively targeting the service and repair business. He also accurately predicted many shops would take on additional service lines, and he’s brought many trend-setting marketing m arketing and sales techniques to our industr y. Join us, and not only will Bob shares his vision of the future with you, but you will have the rare opportunity during each Q&A session to nd the answers you have been looking for that will take you and your shop right to the top. This youthe willfuture learn of at the this auto powerful, interactive session:   is what What repair industry holds for you   What the new car dealers are doing and why   How to nd and hire the stars during these changing times   How to best market to today’s savvy consumer   Benchmarks of the top shops in America   How to drive up sales, prots and the value of your shop

october 28

8:00am - 3:00pm Attendee Registration

8:00am - 9:00am ATRA Member Meeting 9:00am - 12:00pm Technical & Technical  & Management Management Seminars  Seminars



1:00pm - 5:00pm Management Seminars Management  Seminars





1:00pm - 6:00pm Technical Seminars Technical  Seminars







1:00pm - 3:00pm Management Seminars Success or Struggle? You Decide! Maylan Newton (ESi)  How do you see the world? Believe it or not, how you perceive your business has a lot to do with your success… or lack of it. In this seminar, Maylan denes and categorizes some of the most common personality types and attitudes in today’s shop owners, and shows how those attitudes can shape their business success, or, in some cases, sabotage their career goals. And he discusses ways you can ca n reinvent your attitudes to help support yourself in the future.

3:00pm - 5:00pm Management Seminars The Four Gears in Online Marketing Danny Sanchez (Autoshop Solutions)  There’s no question consumers are looking to the internet for services. But when they Google phrases like transmission repair, are they going to nd your shop? And will they call when they see your web site? Danny Sanchez, a 23-year automotive veteran, AMI instructor, and president of Au toshop Solutions, will help you understand the Four Gears of online marketing. From web site design, search engine optimization (SEO), search engine marketing (SEM or PPC), to social media marketing, Danny will detail the important factors and key indicators to help you build a strong pres ence and draw more customers.

ATRA’s Powertrain Expo

45

 

 

friday | seminars (cont’d from pg 5)

friday october 28 (cont’d from pg 5)

8:00am - 3:00pm Attendee Registration

8:00am - 9:00am ATRA Member Meeting 9:00am - 12:00pm

Technical & Technical  & Management Management Seminars  Seminars 1:00pm - 5:00pm Management Seminars Management  Seminars

9:00am - 10:00am Technical Tec hnical Seminars A Shop’s Guide to Cost Savings, the Green and Safe Way Carl Mustari (Chattahoochee Tech College)  In these lean times, Carl will present guidance to shop managers on ways to reduce cost through efcient use of enen ergy,, waste oil heaters, shop lighting, recycling waste, ergy wa ste, lters, batteries, etc. Also included is an overview of shop safety with an emphasis on how shops can save their resources so that their overhead can be reduced...the GREEN way.

Focusing on What You Need to Fix Transmissions TODAY Dave Skora (Valve Body Pros)  Dave understands the frustrations technicians face everyday.. If you want help solving problems quickly without a lot day of theory or time-wasting tests, this may be the seminar for you.

10:00am - 11:00am 1:00pm - 6:00pm Technical Seminars Technical  Seminars

Technical Tec hnical Seminars Street Smart: Is It Really a Transmission Transmission Problem? Mike Brown (ATRA)  Before you make a decision to remove the transmission, make sure it’s NOT the transmission.

CAN BUS: A Simplistic But Intuitive View Bill Henney (Bluereach Automation & Control Ltd)   ATRA will be providing power extension cords in designated rows in each seminar room for those attendees that plan on bringing their laptops. These spaces are limited so please plan to arrive early.

A simple to understand look at why we need the CAN system and how it affects us in the transmission industry. After this session, you will be able to condently work on CAN enabled vehicles. We We will also look at the principal of the Lepellitier model.

46

ATRA’s Powertrain Expo

 

 

seminars | friday they impact your repairs on this unit. Parts interchangeability interchangeability is becoming an issue with this unit and a nd we will explore the interchange issues regarding the updated parts.

11:00am - 12:00pm Technical Tec hnical Seminars Diagnostic Breakdowns Sean Boyle (Southern Illinois University)  Money and time aren’t the only things lost when a repair comes back - customer condence is lost as well.   Learn effective diagnostic strategies   Determine the root-cause of failures   Learn how to approach no-code diagnostics   Learn how to avoid diagnostic failures and misdirection •







Servicing & Repairing Chrysler Transmissions A to Z Alan McAvory (Chrysler Midwest Business Center)  This presentation includes an update on current Chrysler Automatic Transmission application, diagnostic, diagnostic, service and repair procedures. procedures. An overview on how to access to Chr Chr-syler Service information, interpretation of Scan Tool data and Flash Programing procedures: Application and Identication Service Information and Maintenance Accessing Chrysler Service & Parts Information Diagnosis & Repair Scan Tool Information DTC Event Data Flash Programming Electrical Connector Repairs •













2:45pm - 4:15pm Technical Te chnical Seminars What Are You Doing to Reduce Comebacks? Bill Brayton (ATRA)  This seminar/discussion forum will bring techniques and procedures used by top builders/owners in the industry to reduce comebacks in their shops. This seminar will look at late model transmission problem areas and methods used to solve these problems whether it is with a product or a procedure that the t he technicians created to solve his/her particular issue.

Vital Voltage Drop Tests You Should Know Dan Marinucci (Communiqué)  First, Dan covers the basics of voltage drop testing. Then First, he applies that knowledge to solving some common electrical problems technicians technicians encounter. Both experienced and inexperienced techs will appreciate the practical tips presented here!   Theory of voltage drop   Practical applications of voltage drop   Problem solving with voltage drop   Typical voltage drop values   Money-making tips on this technique •











4:30pm - 6:00pm

1:00pm - 2:30pm

Technical Te chnical Seminars

Technical Tec hnical Seminars Electro-Hydraulic & Mechatronic Control Bob Warnke (Sonnax)  Common problems and methods for diagnosis: AISIN 6 speeds AISIN 55-50/51 ZF 6 HP/Ford 6R60 722.6 / NAG1 / 722.9 Chrysler 545RFE Ford 6R140 Ford 5R110 GM 6L80E / 6T40E •











Is It the Torque Converter or the Transmission?  Joe Rivera (ProTorque)  (ProTorque)   Joe takes you through a journey journey of problems that can easily easily be xed. This seminar will cover the most common problems associated with the torque converter and how to repair it.





LCT 1000 Problems & Updates Steve Garrett (ATRA)  We will take a look at the problems you commonly face

Ford Powertrain -- Fixing It Right The First Time Stevie LaVallee (TEST Research)  Stevie will be covering late model Ford transmissions including the newer six speeds and the increasingly popular CVT. Learn the principles of operation, systematic diagnostic

with the LCT 1000. How do you diagnose them and how do you repair them. In addition, we look at the “MAJOR” product changes for the 2010-2011 model years and how

routines, repair tips, and the importance of using ash reprogramming strategy revisions in the repair process.

 

 

saturday | seminars

saturday

9:00am - 12:00pm Management Seminars

october 29

Scott Harris (Mustang We’ve discovered through Marketing)  the What’s Working study that

7:00am - 9:00am Chapter President’s Meeting 8:00am - 3:00pm Attendee Registration

9:00am - 12:00pm Technical & Technical  & Management Management Seminars  Seminars 1:00pm - 2:00pm ATRA Luncheon 2:00pm - 5:00pm Trade Show Open 5:00pm - 7:00pm Cocktail Reception

Creating a Customer...For Free

one of the most successful ways of generating new customers is by increasing your shop’s involvement in the community.. Part of that means making sure the community knows nity about that involvement! Scott Harris, is the owner and president of Mustang Marketing a full service marketing company specializing in taking their clients right to the top with proven marketing and public relation strategies. In fact, Mustang Marketing is the same company ATRA used to brand the ATRA logo and website to the motoring public. How’s that working? To date, ATRA is the most viewed website in our entire industry!* In this seminar attendees will learn how to create and distribute press releases that not only inform, but promote your company’s true concern for the community it serves. Whether it’s an upcoming car care clinic, local fund raiser, or other event supporting your community – getting the word out in a targeted fashion is a win-win for both your shop and the event it’s supporting – and the best part is, done right, most if not all of the promotion is absolutely free! – So make sure to pencil in this special bonus seminar at this year’s expo.

Step Into The Thinking Room Coach Ron Tunic (CRT Broadcasting) 

Our Guarantee To You:

We’re so confident of  your complete complete satisfaction satisfaction of our Technical & Management seminars, we’ll guarantee it in writing: If, for any reason,  you aren’t 100% satisfied satisfied with the information and material you’ve received; we will refund your entire registration fees!

 Join Coach Ron for an inspiring session session designed to help you think like a leader, and more importantly importantly,, how to think for yourself. Learn to think the right way and you’ll make better choices. Make better choices and you’ll see better opportunities. Learn how to think and you will gain strength, self-condence and the ability to lead. If you’re ready to take the leadership role in your own life, then you’re ready for the Thinking Room!

48

ATRA’s Powertrain Expo

 

  9:00am - 10:30am Technical Techni cal Seminars Real World Problems & Corrections

 John Parmenter Parmenter Interna International)  tional)  fast! Get those cars xed(Precision and back to the customer… That’s always your goal, and this class will help you do  just that. John will cover the xes, xes, R&R tips and tricks, as well as pertinent items you never want to overlook during the rebuilding process.

Hybrid Service & Repair for Transmiss Transmission ion Techs  Jack Rosebro (Perfect (Perfect Sky)  When servicing or repairing a hybrid transaxle or transmission, when do you need to disable a hybrid’s high-voltage system, and how do you do it? How do you determine that the system is safe to work on? How do you know a hybrid transaxle performance issue is not cause by that the vehicle’s battery pack or inverter? We’ll discuss those issues as well as the more common hybrid transaxle faults that technicians are seeing in the eld.

10:30am - 12:00pm Technical Techni cal Seminars 4EAT, Phase II, 4AT or 5AT Whis Is It? Mike Souza (ATRA)  A look at the changes the 4 speed transmission has gone through along between with the introduction of the 5AT The similarities both the 4 speed and55speed. speed transmission.

Chrysler CVT & Product Line Tests Tests and Reviews Randall Schroeder (ATRA)  This class will delve into the Chrysler CVT: all the “things you need to know” when repairing and testing these increas ingly common units. Along with the CVT information, you’ll learn how to deal with problems and xes for the TE/AE, RE and RFE families of transmissions, followed by a questionand-answer session.

seminars | saturday

ATRA’s Powertrain Expo

49

 

 

sunday | seminars

sunday

9:00am - 12:00pm Management Seminars

october 31

with Scott Whether yourJohnson  customers are on a train, in a plane, under a

8:00am - 10:00am Supplier Meeting & Exhibitor Booth Drawing 9:00am - 2:00pm Attendee Registration 9:00am - 12:00pm

Technical & Technical  & Management Management Seminars  Seminars 12:00pm - 5:00pm Trade Show Open 4:00pm - 5:00pm ATRA Longtimers’ Longtimers’ Meeting

Green Eggs & Ham Power Breakfast

box, or with a fox, you can bet they do not want to buy a new transmission simply because that’s what you have to sell. In this early morning breakfast seminar, Scott will explain the differences between a commodity-based business and a service-oriented one. And you’ll learn how critical it is to discover the needs of your customers, and how to address those needs. Come in early and join us for breakfast; no green eggs or ham… guaranteed!

Round Table Q&A What’s Working Management Team  Team  Immediately after the breakfast seminar, stick around for a round table discussion covering the concepts we’ve been discussing over the last few days. This Q&A will be hosted by a few of our esteemed seminar trainers, and we’ll have several shop owners on hand who’ve turned their businesses around by transforming their attitudes and rethinking the way they approach their customers. This is your chance to chime in and clarify the notions you’ve been learning, and turn them into a new beginning for your business… and your future. Don’t miss it!

9:00am - 10:30am Technicall Seminars Technica

10:30am - 12:00pm Technical Seminars

Supplier Showcase: Sonnax

Supplier Showcase: Mustang Dyno

Supplier Showcase: Auto Research & Design

50

ATRA’s Powertrain Expo

 

A & Reds Transmission Parts Adapt-A-Case Alto Products Corporation Amsoil Synthetic Lubricant Lubricantss ATRA Automotive Research & Design, LLC Autoshop Solutions, Inc. BorgWarner Central Valve Bodies Chrysler-Mopar Dacco, Inc. Demandforce, Inc. Educational Seminars Institute (ESi) Equipment Manufacturing Corp. ETE Reman EVT Parts Exedy Friction Technics Ford Customer Service Division G Cor Automotive Gandrud Parts Center GEARS  Magazine  Magazine General Motors GFX Corp. G-Tec Inc. Hayden Automotive HGM Electronics/PML Inc.  Jasper Engines & Transmissio Transmissions ns  JDS Worldwide Worldwide Corp. KRS International Kuhle Lintex Auto Parts Co., LTD

Management Feedback Systems, Inc. Mustang Advanced Engineering NATPRO Northland Transmission Inc. Oklahoma Transmission Supply, Inc. (OTS) Omega Machine & Tool, Inc. Power Pusher by Nu*Star, Inc. Precision International Precision of New Hampton/Hot Flush Raybestos Powertrain Rostra Precision Controls, Inc. Seal Aftermarket Products Slauson Transmission Parts Smart Blend Synthetics By Life Automotive Products Sonnax STK Transmission Parts Co., LTD SuperFlow Technologies Group Superior Transmission Parts, Inc. TRANSBRITE / Allen Woods & Assocates Transmission Digest Transmission Transmis sion Rebuilders Network Int’l (TRNi) Transmission Transmis sion Rebuilders Network Worldwid Worldwide e (TRNW) Transmission Specialties, Inc. Transtar Industries TransTec by Corteco Valeo Transmissions Valve Body Pro VBX-Valve Body Xpress

Lubegard by International Lubricants, Inc.

Whatever-It-Takes Transmission

exhibit hours

2:00pm - 5:00pm Saturday

ProtBoost Software, LLC

12:00pm - 5:00pm Sunday 9:00am - 2:00pm Monday

co-hosted with

A.I.M. Auto Suppliers Limited BPS Cores, Inc. Car-Part.com D&V Electronics Ltd. D&W Diesel, Inc. DCM Tech, Corp.

International Automotive Trading, Inc.  J&N Auto Electric Knopf Automotive LLC LR Miller Company, Inc. Lewis Tool & Die, Inc. LKQ Corporation Lock-N-Stitch Inc.

Rebuilders Automotive Supply Company Regitar U.S.A., Inc. Romaine Electric Corporation Shenzhen Meridian Parts Company STC Automotive, Inc. Taditel U.S., Inc The Recycler Core Company Inc.

Dixie Electric Ltd DS USA Ltd. DuBois Marketing Inc.

Phoenix Automotive Cores ProDiesel Quality Equipment Sales

Wagner Alternators & Supplies, Inc. W Alglobal - Wetherill Associates Inc. Xiamen Sunny General Machinery &

 e   x   h    i       b     i        t       o   r     s  

Green Global Parts, Inc. Guspro, Inc.

Rand Premium Electronics RCP RC P, Inc. I nc.

Electrical Co, Ltd Zerust Corrosion Products

ATRA’s Powertrain Expo

51

 

special events

 

friday, 10/28 8:00am - 9:00am

sunday, 10/30 sunday, 10/3 0 8:00am - 9:00am

ATRA Member Meeting

Industry Supplier Meeting

You’ve heard he ard it before: ATRA is your Association .

As a Supplier, your needs are different from those

And the Member Meeting is your opportunity to give voice to your opinions. This is the one time every year that the ATRA Board and staff all meet together in a forum with its Members to learn what you want from ATRA. It’s your opportunity to help shape ATRA’s ATRA’s future. Don’t miss out: Whether you’re you ’re a Member or planning on becoming one, make plans to join us at this year’s Member Meeting.

of shop owners. You You know it and so do we. That’s why we’re holding our frst ever Industry Supplier Meeting, right before the Exhibitor Booth Drawing. We want to hear your thoughts and learn how we can better serve the supply side of our industry. Drop by, by, enjoy a continental breakfast on us, and let’s discuss how we can address your needs.

saturday, 10/29

sunday, 10/30 sunday, 10/3 0 9:00am - 10:00am

1:00pm - 2:00pm

2012 Exhibitor Booth Drawing

ATRA Luncheon

Immediately following the Industry Supplier Meeting, stay for the Booth Drawing and reserve your spot for the 2012 Expo to be held at Bally’s in Las Vegas. Once again, sharing space with APRA and leading into Industry Week.

After an intense morning of seminars, it’s time to sit down to a sumptuous luncheon, courtesy of ATRA ATRA.. This is your frst real chance to rub elbows and break bread with friends, old and new new.. Of course, this is more than just a meal: It’s your chance to enjoy entertainment, discuss what you’ve been learning, and recharge your batteries as you prepare to “shift gears” for an afternoon exploring new products and services on the Expo show oor.

saturday, 10/29 5:00pm - 7:00pm

Cocktail Reception For many, many, Expo doesn’t really kick into high gear until the annual Cocktail Reception, as always, hosted by Transtar Industries. Live music, an open bar, and a wide selection of tasty hors d’oeuvres are the backdrop for an evening of fun and revelr y, catching up with old friends, and meeting revelry new ones. It’s the industry networking event of the year!

52

ATRA’s Powertrain Expo

 

  What Works W orks Best For You? You? erence  fe e Con f  te e t Comp l le  t.. 3 0 Oc t  T h  huurs., Oc t  t.. 2 7  7  -   - Suna t., te   l   w i l  l l   you w  tendee yo

erence  e Con f fe  te e t  t   As a Comp l le  managemen t &    l   l a c  ic  i n  hn  h c e    te t  l   l  l a  to   y   e access to  ve  tuurda y a v  ha  h  the Sa t   he  y,, t a y d n u S    h   h g u o r    hr h  t t    y   huursda y  T h  brea k s,  sem i innars T  fee br , co f fe n o    io i  t p e c e  Re R    l   l  i a  ta  t eon & Coc k   he o w   ho  Luunc h  L  Trade S h  y  Tr  Monda y  M &    y   y a d n u S   ,  y,  y a  tuurd ca l l   Sa t  hnn i ic  Tec h  the Te   he g t n  in  i n  in  i a  ta  t n o c   s r e  b i innd m   ion, b adm i isss io sem i innar progra    l   l a c  ic  i n  hn  h c e  Te T   , s  ts  t ou  to  rin t  t  p in o  erpo i inn t  we o w  ria l lss,. Aud i io  Po  P e ia  te  t  ma t  t e e    he h s    k  k  r o  w w    t   t n e  Managem erence  C D and M e Con f fe  te e t  le  l p m o C    l   l  l a   o  to t    led  be ma i le l  b  w i l  l l  C Ds w po.  xp  E x  the E   he  ter t  tendees a f te a t te

Oct. 27 - 31 Las Vegas, NV Las Vegas Hilton 

T e  e c  c h  hn  n  i i c     a  c M a  al l  o r  a n  na    g  a   e  r  g   e   m m    e e    n n    T h  t t    hu   ur  C  o o    r  s  s ,  n n     . , O c  f e  e r  re     n  c t  e t.  27  -  S  f  nc     e  c e  u u    n n    At t  .    ,  , te   en    O  n   d  d e i i t  c c    t t    . 30  th  h   e  er  r  t h  he     T e  e ec    h  s e  e m  c m  h   

ii  n  ni i  c  n  na    r  ca    l l  o r  a r  s  a s T h  hu  r M a  u  r  r  s  s d  d   a n  a a    na     g  y y  a   ge    m  t  h h    e    e  r r    o o    Lu n  m u u    en  nc    h  g g    n   t  c  he  h h    t    o  e   n  S u  u   o n n    n   & C o  d d    a a    y y     ,   , t  o c  h h    c   e e  k k      t t    S  a a    a a    i il l  R e  t u  t  ur  r  d  ec    e  da     y  S a  c   p  a a t  e   t  tu  y  u  r  p r  d  d a  t i i  o  o n  ay  n , ,   c o  y  , ,   S u  o   u   n n    f f    f f    d d    e e    e e    a a    y y    a d  b  & dm     i is  r r    e e      m M  a a    s   s  k k    o o    s i io  s , ,    s     n  nd  n     a  o d n , ,   a n  a y  y T r  nd     b i i n  d ra     d  a de     S h  e nd     e  d e   h   P o  r r    o o    o w  s s    w w  we     r  c    e o o    rp    o  nt  n  p   i i  n  t  a  o ai i  n  nt  ni i  n  t  p r  ng     t h  g ri i  n  n t  he     T e  to     u  e o ut  t s  ec    h  s  , ,   T e  c h  n  e   n   i ic  c c      a  C D  c    l l  h h    a D o r  n n    i i    c c    a a    r M a  l l    s  e e    an  m m    n   a  i i    ag   ge  n n    a a      m  r r  e   e    p  m    n  r r    e o o    nt  gr  g  t  w o  r  a  a m  m  or  r  k  k s  sh  h  e    e  e   t  e t  m a  at  t  e  er  r  i i a  a l ls  s . 

Trade Show Pass Sat., Oct. 29 - Mon., Oct. 31 Your Trade Show Pass will give you access to three full days in the exhibit hall and two shows under one roof! ATRA & APRA have joined forces once again to bring you more than 100 exhibitors!

r   e   g  i     s   t   r  a   t   i     o  n     o  p   t   i     o  n   s 

ATRA’s Powertrain Expo

53

 

 

frequently asked questions what if i want to attend more than one seminar in a session?

can i register at the door? Yes. The following are the dates and times for On-Site Registration: Thursday, October 27: 2pm - 6pm   Friday, October 28: 8am - 3pm   dya, yO ,O oe bre3r 0 2:9: Suantudra ctcotb Monday, October 31:

There will be audio tapes available for all of the seminar sessions.. All complete conference registrants will receive a free sessions audio CD which will be mailed at the end of the Expo.

4 Easy Ways to Register

8am - 2 3pm   9 9am - 1pm  

 

Call:

(800) 428-8489 or (805) 604-2000 

what are the hotel rates?

Online:

www.powertrainexpo.com 

Send Reg form (805) 988-6761 by fax:  ATRA Powertrain Expo Registration  Send Reg form 2400 Latigo Ave  by mail:  Oxnard, CA 93030 

ATRA has negotiated a $105 per night room rate for the nights of October 25 - 29 and $169 per night for the nights of October 30 - November 1. The cut-off dates for these special rates is October 6. To make your reservations please call the hotel directly at (800) 635-7711 and mention ATRA.

does ATRA make make hotel reservations or is it included in the cost of registration? All attendees make their own hotel accommodations directly with the Las Vegas Hilton by calling (800) 635-7711. Mention ATRA to receive your discount room rate. Room reservations are not included with your conference registration.

what are the registration cut-off dates for Expo? The early registration cut-off date at the discount price is 9/16/11. The late registration cut-off date is 10/14/11. Any registrations made made after 10/14/11 will need to be done on-site at the event.

did you receive my registration? am i registered? Your conrmation will automatically ly be mailed to you immediately after your registration is processed. Please contact ATRA at (800) 428-8489 if you have not received your conrmation.

does my guest need to register? Yes, everyone attending the seminars or trade show must have an ofcial badge and registration - except babies in strollers. Spouses and children of conference registrants may be eligible to receive free trade show access. Please call for details details..

can i change one of my paid registrations from one person to another? Yes, you can switch the name on one or more of your registrations up to 10 days before the event at no charge. Any changes made within 10 days of the event will be charged $10 each. Call (800) 428-8489 with any changes you’d you ’d like to make.

Registration Information Enrollment is on a rst-come rst-come,, rst-serve basis. Seating is limited by room size. Seminars start promptly at their scheduled time. Arrive early to be sure of good seating, and to meet with instructors and other seminar attendees. Recording is not permitted .

What’s Included   Complete Conference: admission to all technical & management seminars Thursday through Sunday, Saturday Luncheon & Cocktail Reception, coffee breaks, Saturday, Sunday & Monday Trade Show admission, binders containing the Technical Powerpoint printouts, Technical seminar program CD and Management worksheet materials. Audio CDs will be mailed to all Complete Conference attendees after the Expo.   Technical or Management Conference: admission to either the Technica Technicall or Management seminars Thursday through

Sunday, Saturday Luncheon & Cocktail Reception, coffee breaks, Saturday, Sunday & Monday Trade Show admission, and binders containing the Technical Powerpoint printouts, Technical seminar program CD or Management worksheet materials.  

Trade Show: admission to the trade show only

Cancellation Policy All cancellation requests must be made in writing and mailed to: ATRA’s Powertrain Expo Registration, 2400 Latigo Ave, Oxnard, CA 93030 or FAX to (805) 988-6761. Cancellations received before September 16, 2011 will be subject to a 5% cancellation fee. Cancellations received between September 17, 2011 and October 14, 2011 will be subject to a 15% cancellation fee. Cancellations ons received after October 14, 2011 will be subject to a 25% cancellation fee. There will be no exceptions to this policy.

54

ATRA’s Powertrain Expo

 

 

Registration Form October 27th - 31st, 2011 Las Vegas, NV Company Name

ATRA Account Number 

Contact Person: (will receive all correspondence) 

Address

City

State

Zip 

Country 

Area Code Phone No.

(

Fax No.

)

(

)

Email Address 

TO REGISTER: REGISTER: Call toll free 1-800-428-8489 or FAX FAX this completed form to 805-988-6761 Badges will be issued from this list. Use a separate sheet for additional registrations.* 

CONFERENCES

Other

PLEASE PRINT CLEARL CLEARLY Y

(Includes Luncheon and Trade Show) 

Categories

  Complete Conference Technical 

Management

Trade Show 

Luncheon

NAME ___________ ________________________ _________________________ _________________________ _________________________ _________________________ _________________ ____

£ 

£ 

£

£

£

NAME ___________ ________________________ _________________________ _________________________ _________________________ _________________________ _________________ ____

£ 

£ 

£ 

£

£

NAME ___________   ________________________ _________________________ _________________________ _________________________ _________________________ _________________  ____ 

£ 

£ 

£ 

£

£

NAME ___________ ________________________ _________________________ _________________________ _________________________ _________________________ _________________  ____   

£ 

£ 

£ 

£

£

NAME ___________ ________________________ _________________________ _________________________ _________________________ _________________________ _________________  ____   

£ 

£ 

£ 

£

£

Every 5th Conference attendee is free! Call ATRA for details 

Discount for current ATRA Members only. only. Join today and enjoy the member discount right away!

 

Before Sept. 16th 

REGISTRATION FEES

Qty

Complete Conference Registrant* 

_____

Technicall or Managemen Technica Managementt Conference*

Member  

Sept. 17th - Oct. 14 th 

ALL

Non Mem

Member

Non Mem 

ON-SITE

SUBTOTAL

$ 395

$ 495

$ 445

$ 545

$ 595

$____________ 

_____

345

445

395

495

545

$____________ 

Trade Show

_____

10

10

10

10

30

$____________ 

Extra Luncheon Ticket

_____

45

45

45

45

65

$____________  $_________ ___ 

TOTAL

$____________ 

(Included with Complete, Tech & Management Conferences) 

 

* Conference Conference Registrants may receive Trade Show Passes for spouse and/or children by contacting ATRA Registration at 1-800-428-8489. I do not  wish  wish to receive any advertising or promotional material from Exhibitors.

PAYMENT INFORMATION * Check enclosed payable and mail to: ATRA, 2400 Latigo Avenue, Oxnard, CA * MasterCard  * Visa  * AMEX  * Discover Charge to: 

93030

Card Number _____________ ____________________________ _____________________________ _____________________________ _________________ Expiration Date

Check # __________________ ___________________

Security Code

Print Name on Card ______________ _____________________________ _____________________________ _____________________________ ________________________ _________

Signature______________ ____________________________ _____________________________ _____________________  ______ 

 

  Powertrain Expo & Big R Show    0  0  1   1  O v e r  r r y  y     t t  s  u  d  n  I n    s    e e  i  n  a  i r r   C o m p  t  e    h h t    in g  i  n    t t  i    b b  i  s     h h  t s  c  e x  u  d  o  p r o  p    t t  s    e e  t  a  l a  e s ! !    c c  i    v v  r  e  s e  & s

Your Trade Show Pass gives you admission to 2 shows under 1 roof!

O f    c  c i  ia     l l K  a i c  i  ck  O f f  k  -  -    f t o  o I n  nd    u  d   s  u s   t  tr  r  y  y  W e e  e k  k! !   S E  EM    A M    &    AAP E  EX   X s h  ho    w  o   s  w i m  s    mm   me   ed    i i  a  d at  t e    l l  y  e y  f o  ol l  l l o  ow     ! !  w

Together Again!

Trade Show Dates October 29 - 31

Las Vegas Hilton Las Vegas, NV

 

FROM THE THE TECH  TECH DIRECTOR

It’s All About Communication I

was sitting at the kitchen counter a few weeks ago, talking to my  brother about his 2004 F150. We needed to replace the clutch fluid: His truck has 260,000+ miles on it and the fluid looked like chocolate milk. As we were talking, my 16-year-

old daughter Paige was sitting with us. Suddenly she started giggling hysterically. When I asked what was so funny, she replied, “You guys are talking a totally different language. I have no idea what you’re saying.” I chuckled, and explained what we

by Lance Wiggins members.atra.com www.atra.com

were talking about: What the clutch is, how it works, what the fluid does, and why it needed to be replaced. I found myself explaining the repair in very simple terms, and it worked. She understood what we were going to do and it made sense to her.

58

GEARS May/June 2011

 

One of the services we’ve been offering lately at ATRA has been to answer consumer questions. We get about 60 emails a month through the ATRA.com web site. Imagine how this would have  played out if the situation were a little different: Instead of my daughter listening to a conversation about my brother’s truck, supposed she’d been a customer asking about her car. The customer’s already stressed  because her car has a problem. Add to that the difficulty in asking a stranger for help. And now she’s fighting to understand an explanation laced with  jargon and tech-speak. tech-speak. Some customers would head straight for the door. And who could  blame them? a saying that goes, “If There’s you can’t dazzle them with brilliance,  baffle them with BS.” It’s It’s a funny line, and in some situations it might even be a good strategy. But not when you’re dealing with a customer who’s come to your shop with a problem. There it’s  just bad business. Remember, the customer’s concerns go deeper than just “what’s wrong,” or even whether you know how to fix it. They’re also concerned with whether you’re being honest with them and giving them a fair price for work they really need. This can be especially true with women who’ve never dealt with you or

Slauson Transmission Parts Making Hard Parts … Simple

Experti se saves you time, money and Our Hard Parts Expertise headaches.. We can do every thing the BIG BOYS  headaches can – and then some!  Because, when it comes to Hard Parts we literally   Wrote  Wrote the Book. In fact, you probably have a Slauson Book  in  in your shop right now ... and so do most other parts suppliers. Not only that, but we were the  first to create a digital catalog   and ordering system, again setting the industry

Used, New  and Rebuilt Hard Parts Soft Par ts Electrical Components & Flywheels

standard  for  for Hard Parts identification. The 2011

 

 S l a u s o n B o o k available now at Slauson.com

Order Online 24/7 at www.slauson.com  Phone Hours: 7:00 am to 5:00 pm/ PST 

… ask about custom catalogs for your

your shop before. They’re often uneasy about the reputation of auto mechanics:

Call (800) 421-5580 • Local (310) 768-2099 FAX ( 310) 768-8298 • Se habla Español!

GEARS May/June 2011

business

59

 

It’s All About Communication

“They’ll sell you whatever they want  because they figure we won’t know the difference.” By using big words and industry jargon, you’re just reinforcing their fears. The key is learning to speak to  the customer; not at  her…   her… or him. You have to reach out to her on her level, and make sure she’s comfortable with your explanation. That connection is essential for helping develop the trust that’s a critical  part of the equation that defines customer service. One of the services we’ve  been offering lately at ATRA has  been to answer consumer questions. We get about 60 emails a month through the ATRA.com web site. Sometimes those questions are very technical. But most of the time, they’re asking us to verify what they’ve been told, because they’re experiencing a trust issue with a shop or technician. My job is to answer those questions as clearly as I can. Very often that means breaking my explanations down into simple terms and concepts. Words and abbreviations that we take for granted — like TPS  or  or  EGR — have no real meaning to the consumer. So I have to explain those concepts in simpler terms. And I have to relate those systems to the problem they’re having, so they know why it could affect their car’s operation. the same time,aI always  pointAt them toward nearby ATRA Member shop to help them through the specific conditions. That way, if there’s additional service necessary, we can help them work through the problem and come up with a solution that’ll satisfy the consumer. The object isn’t just to fix their cars; it’s also to make sure they’re comfortable with the solutions. And most importantly, we want to make sure they feel good about having contacted ATRA and  brought their cars to an ATRA Member shop. Since we began offering this

are planning to refer ATRA and the ATRA Member shop to their friends. It’s an important step toward building ATRA’s reputation as the name to trust for transmission service and

repair. But it’s not something we can do alone. You need to do your part by remembering a key element of consumer trust is all about communication.

 program, I’ve received over 300 response emails from consumers who’ve had their cars fixed, and

60

GEARS May/June 2011

 

DRIVING Customers TO Y O U  

 ATRA.com  A TRA.com has become the most visited    Web  W eb site in the transmission industr industry y. 

Thousands Thous ands of new new customers customers have been been using using ATRA ATRA’’s  Weeb si  W site te to fin findd trtraans nsm miss ssiion re reppai airr sh shoops in th theeir ar areea.

Is your shop one of them? It can be. Being an ATRA member means means ATRA will place a link lin k to your Web Web site on ATRA.com, where customers can use the local search feature to find shops in their area. This tool is beginning to appear in top search results for transmission repair on Google. This means people looking for shops in search engines are being directed to ATRA’s Web site and ATRA members.

Your Web site is an essential tool to get transmissions in need of repair into your shop. Now it can be even more powerful. Join ATRA ATRA today and start reaping the benefits of ATRA’s ATRA’s Web presence.

The page views have doubled since the launch of ATRA’ ATRA’ss local search feature. fe ature. That’s Th at’s potential business you cannot even begin to gain strictly from word-of-mouth referrals.

 ATRA.com   A TRA.com 

 

Visit members.ATRA.com    or call 8 0 5 - 6 0 4 - 2 0 0 0

AUTOMATIC TRANSMISSION REBUILDERS ASSOCIATION

 

Sometimes a Rebuild Isn’t the Only Answer

by Steve Bodofsky members.atra.com www.atra.com

or years the answer was fairly simple… and pretty much the same in every transmission

F

 pieced out until they had a lot of miles on them. And remans hadn’t become a viable solution… yet.

shops or individuals to install themselves. The bulk of his business is selling remans and used transmissions. He has a fulltime outside sales person, Kimberly Hepburn, who introduces other shops to their product line and services. Used transmissions? How can that  be profitable? Funny thing about that:

shop across the country. If the transmission is broken, you had one choice: rebuild it. Simple, right? Maybe not. In fact, today, a number of shops are proving that the “rebuild only” business model isn’t the only way to run a successful transmission transmission shop. For years now, ATRA’s CEO Dennis Madden has stressed the importance of discovering and addressing your customers’ needs. It’s a legitimate consideration, and one that’s easy to forget about when confronted with the dollar signs for a transmission rebuild.

Today a lot has changed in the transmission business (seriously, is there any way I can get paid for every time I say that?) Today, $3000 for a rebuild may mean the customer got lucky! But those changes have created a number of viable options for you and your customers… options that make it possible for you to help meet their financial needs, while still allowing you to earn a reasonable profit. Those options include remans, targeted repairs, and even used units.

While our business was changing, so was the insurance industry. And today, many cars are totaled simply because the airbags deployed. Which means there are a lot of used transmissions available with only 10 to 20 thousand miles on them — just broken in. What’s more, some of those transmissions are available for just a couple hundred dollars. So Glen Burnie’s technicians can install a used unit for anywhere from $1200 to $1700 and still make just as much as they would have with a rebuild. And the customer saves

mind cost. that one needsKeep oftenininvolves Sure,of thethose customer’s transmission is broken or worn out; he has to get it fixed if he’s going to put his car back on the road. But if he can’t scrape together the $3500 to pay for a full rebuild, nothing you can say or do is going to change that. The rebuild-only mentality began in a different era. Back then a rebuild would cost maybe $300 or $400 — a lot of money in those days, but there wasn’t much you could save and still  provide a respectable repair. repair. Once you had the transmission on the bench you were committed to the bulk of the job. The parts were only a few bucks, so skipping a clutch pack wasn’t going to

Think that’sto just giving up? Orowngiving in? I talked a couple shop ers who are taking advantage of those options and are enjoying record sales  because of them. Six years ago, Glen Burnie Transmissions in Maryland was just scraping by, according to shop owner Mark Schwartzman. They had over 50 employees, including nine rebuilders. Then Mark transformed his way of thinking: He started by becoming a regional distributor for Certified Transmission. Today Glen Burnie has 18 employees and no rebuilders. And last year they did nearly $6 million in business! A fluke? This year he’s on track to

$1000 more on the job.“I’ve already AsorMark explains, spent the money for advertising to  bring the customers in the door. It makes no sense to let them walk out  just because they can’t afford a $3000 repair… not when I can offer them a lower-cost alternative, and still make a good profit.” The salvage yard offers Mark a 6-month, 6000-mile warranty on its used units, and allows him to extend the warranty for just a few bucks more. Of course, not every transmission can be purchased used. Some are known to have too many problems; others cost too much to be profitable, when they’re available at all.

save anything. Used transmissions? They were a crapshoot, because cars didn’t get

 beat those sales by about 2%. Between 15-18% of those sales are “carryout” units; transmissions bought by other

And mileage matters: On one car, 20–30,000 miles is about the limit for accepting a used transmission. On oth-

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ers, 60–70,000 is still fine, as long as the oil looks clean and the price is reasonable. This is where experience comes in: You have to know which transmissions are worth trying and which aren’t a good risk. Take a look through your records for the last few years. Does the unit tend to fail around 80,000 miles? Then you won’t want to install anything with much more than 20,000 miles. But if the average mileage for a failure tends to be closer to a quarter million miles, 60,000 miles is barely a drop

accept half the risk. If the job cost $1600, and the transmission fails while it’s under the warranty, Dave credits the customer $800 toward the price of a rebuild. As Dave sees it, he made money on the repair, so if he has to cut into his profit on a rebuild to keep the customer happy, it’s worth it. And since his rebuilders went through the unit, he knows his risk is limited. How limited? limited? Over the last year, only one transmission had to come back for a warranty rebuild after a targeted repair. Not a bad average.

in the Ofbucket. course, Mark is an extreme case. He’s completely transformed his business model from the standard transmission repair shop. But Glen Burnie Transmissions isn’t the only shop that’s offering its customers alternatives to the high price of rebuilds. Dave Riccio of Tri-City Transmission is doing it, too (see the profile on Tri-City in the January/February 2011 issue of GEARS ). ). And Dave has added another service alternative to the mix: targeted repair. Sure, every transmission shop will replace a solenoid or a valve body without selling a full rebuild. But once the unit reaches the bench, most shops insist on going the rebuild route. This is where Dave differs. “We’ll sometimes install just a torque converter in a car with 90,000 miles. Some shop owners think I’m crazy for doing that. But if the converter is the only problem and the customer really can’t afford a rebuild, why not? We make a buck on the job and the customer gets his car back on the road.” Another place where Tri-City can sometimes save its customers money is on front-wheel drive units, where the differential is quiet and working okay. In that case they might agree to leave the differential alone, and not run the case through the parts washer. The customer saves a few hundred dollars on the job, and still gets a transmission that works like it just had a complete rebuild. A big difference with today’s transmissions is parts cost. Twenty years ago the clutches in a transmission might have cost only five or ten bucks; there was no savings in rebuild-

addition to warranty explaining the which process to the the customer, DaveInhas a special form, explains service that was performed and the limits of the warranty. So the customer should be well informed about the repair he paid for, and the coverage he’s receiving. That’s important, because, left to their own devices, customers will remember that their transmission got fixed and that they paid $1600 for it — still a lot of money to them. The nuances of the repair and the difference between a targeted repair and a rebuild can slip away over time. That’s why it’s critical to spend the time to explain the differences, and clarify those differences on the repair order and the warranty. Sure, it’s nice to sell a full rebuild. And in some cases a custom rebuild is still the best option for the customer. But sometimes the customers’ needs won’t allow it; they just don’t have the money. That’s okay; today’s changes in the market have created the conditions to provide a new series of options to address those needs… options that can still provide you with a substantial profit… if you’re willing to embrace them.

ing one drum can and easily not thecost others. the clutches today’s transmissions a fewBut hundred dollars.inSo if the customer’s up against it, and one or two clutch packs are okay, there really may be a benefit in rebuilding just the drums that are bad and leaving the rest alone. Tri-City also offers used transmissions when they’re available and are a reasonable alternative. But they go a step further: They open the unit and check the clutches. Then they replace the filter and the outside seals, and fill it with new oil. That way they’re fairly confident that the used transmission won’t leak, and will hold up for a reasonable amount of time. One of the most critical considerations when offering the customer a lower-cost alternative is communication. Dave makes sure the customer understands that he isn’t getting a rebuilt transmission, and that the job may involve a bit of risk. And Dave offers to share that risk with the customer. With used transmissions or targeted repairs, Dave offers a limited, one-year, 12,000-mile warranty. The warranty is only

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good at Tri-City: He doesn’t offer the Golden Rule Warranty, and there’s no outside coverage, except in special cases. And the warranty is 50-50: Both Dave and the customer

1.888.776.9824 • tciauto.com

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KEEP THOSE TRANNYS ROLLING

A Lincoln with an Attitude

O

ur story begins with a call to the ATRA Technical Hotline from a technician named

Kyle. Kyle said he was working on “a Lincoln with an attitude.” The car in question was a 2003 Lincoln LS equipped with a 3.0L engine, and a 5R55N transmission with harsh shifts at times (Figure 1). According to Kyle, the owner of the vehicle said he’d been having drivability problems for the past few months: erratic engine idle, “Check Engine” light flashing occasionally, engine surge while driving, and of course, harsh shifting. The customer had taken his car to a couple local shops to check the driveability issues. After checking the computer system and replacing several sensors, such as the mass airflow sensor, TPS, and MAP, he was referred to

by Pete Huscher  members.atra.com www.atra.com

Kyle took the vehicle to his local Ford/Lincoln dealership where they reprogrammed the PCM with the latest update. On the way back to the shop the transmission continued to have the occasional harsh shift.

Harsh Shifts Verified Kyle drove the car and immediately felt the harsh shifts. He returned to the shop, connected his scan tool, and checked for codes; there weren’t any. Then Kyle installed his pressure gauge on the line pressure tap for the PCA and PCSB (pressure control solenoids A and B) circuits and headed out for another test drive. During this test drive, PCS  pressure would climb to over 220 PSI at the same time the harsh shifts were taking place. The Lincoln had a pressure problem.

at the PCS solenoid, to see whether the computer was commanding high  pressure. Kyle connected his voltmeter to the PCS circuit (figure 2), close to the PCM (figure 3), and headed out for another test drive. During the test drive, PCS circuit amperage would drop just before PCS  pressure started to rise to 220 PSI (Figure 4). This indicated the computer was actually commanding high line  pressure. With With the computer computer commanding high PCS pressure, it was time to take a look at the computer system.

Kyle to have the transmission operation checked.

Checking PCS Solenoid Command

Checking the Computer System

The next step was to check voltage

Ford has issued several techni-

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GEARS May/June 2011

 

Figure 1

cal bulletins related to programming issues and updates to this PCM, to correct pressure control issues. So I recommended having the PCM reprogrammed with the latest update before spending hours checking PCM inputs, and powers and grounds. Kyle took the vehicle to his local

Figure 2

Ford/Lincoln dealership where they reprogrammed the PCM with the latest update. On the way back to the shop the transmission continued to have the occasional harsh shift. So, when he got  back to the shop, Kyle connected his

scan tool and started checking the PCM inputs. The scan tool showed the inputs were all within specifications, which suggested a faulty PCM. But, as I explained to Kyle, the Lincoln PCM

Figure 3

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65

 

A Lincoln with an Attitude

tions. Then we took another look at the PCM powers and grounds — also all within specifications. All indications  pointed to a faulty PCM (Figure (Figure 5).

Replacing the Powertrain Control Module Kyle contacted his local Ford/ Lincoln dealership to order a new

Figure 4

goes for about $1000; not something you throw in without being sure. I recommended checking each individual input and every power and ground to the PCM before condemning it. Kyle pulled out his meter and started checking each input to the PCM. All were within specifications. Then he checked the PCM powers and

grounds; they were also within specification. With the inputs, powers, and grounds within specifications, Kyle was fairly confident that he was dealing with a faulty PCM, but he was still hesitant to throw a $1000 PCM at the vehicle. So I went over the inputs with him. They were all within specifica-

PCM. They toldit him thetake PCMabout was six on  backorder  backorder, , and would weeks to arrive. So he called me back and asked me to try to help him find a rebuilt PCM. I explained that there was a reason the PCM was on backorder: Ford was having problems with this unit, and a used or rebuilt PCM may come with the same problems. I recommended against installing a used or rebuilt PCM, and suggested waiting for the new PCM to arrive. Kyle agreed. After the new PCM arrived, Kyle installed it, and then took the vehicle to his local Ford/Lincoln dealership to have it programmed for the vehicle,  based on the VIN and security system codes.

Go electronic... CSII is the solution to installing a modern powertrain into your  street rod, nostalgia nostalgia car, car, muscle car, car, race race car or heavy truck.

Kit comes complete with hardware & instruction manual for quick and easy installation. LCD programming display included. Generates trouble codes & live data stream. Shift points and pressure adjustable, self calibrating AccuLink TPS.

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Figure 5

GEARS May/June 2011

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A Lincoln with an Attitude

The Crew at Seven Oaks Transmissi Transmission on L to R: Lawrence Kruk, Garett DeGrave, Bob De Grave, Brian Fischer, Jim Doe, Maverick (Magic) Williams, Kyle DeGrave

Success is at Hand

GEARSMagazine.com

Where the Industry Gathers

GEARSmagazine.com adds more past issues to site. GEARSmagazine.com adds Tired of rummaging through past issues of GEARS for a certain article or topic – can’t remember which issue it was in or if you even have it any-  more?   We hear you! •







Now you can search past issues of GEARS (back to October 2008) with more issues being added every month – it’s easy and Free Complete article search by author, keywords or publication date Plus…. Looking for parts or service? We’ve got you covered here too with the all new GEARS Online Buyers Guide Search by specific category for quick website links to the suppliers of our industry.

Coming Soon – Look for our new blog features and iPowertrian News – updated and timely news and products that will keep you and your shop on top of our ever changing industry. GEARSMAGAZINE.com – The Industry’s Information Site

With the freshly programmed PCM in the vehicle, Kyle was ready to take the car for a test drive to recheck transmission operation. The transmission operated perfectly. The shifts were on time and smooth, each and every time. Kyle has driven the vehicle several times since replacing the PCM, and the transmission always shifts perfectly.

In Closing If you run in to a problem vehicle, and you suspect a possible computer  problem (PCM/TCM/BCM (PCM/TCM/BCM,, etc.), be sure to take the time to check the inputs,  powers, and grounds to the computer  before replacing it. Remember, by performing a thorough diagnosis, you, too, can tame your vehicle’s attitude, and keep those trannies rolling .

GEARS FOR THE TRANSMISSION REBUILDING INDUSTRY 

TM

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MEMBERSHIP MATTERS

You Made the Call and ATRA Answered: You Made the Call and ATRA Answered: 3-Year Golden Rule Warranty Warr anty for All Units You hear it everywhere: It’s  your   country… it’s  your   government… it’s  your   planet. But when it comes down to it, someone else always seems to be calling the shots… and too often the results aren’t what you’d hoped for. Well, when we say ATRA is  your   Association, we really mean it. In a recent Membership Survey, we asked what you’d like ATRA to do for you. The results were overwhelming: extend the 3-year Golden Rule Warranty to cover all transmissions, regardless of manufacturer or age. So that’s exactly what we did. ATRA already offered Members a 3-year warranty, but only for GM, Ford, and Chrysler, and only on transmissions that were less than 10 years old. Effective immediately, ATRA Members can now offer a full 3-year Golden Rule Warranty on all make and model transmissions, regardless of age. The new 3-year warranty takes its place along side ATRA’s already familiar 1and 2-year warranties. Which means you can now complete toe-to-toe with the warranties being offered by reman companies. “This is a terrific example of how ATRA is supposed to work,” explains ATRA CEO Dennis Madden. “When there’s something that our Members need — something that can help them  be more competiti competitive ve and more profitable — it’s our job to make that hap pen. And that’ that’ss exactly what we’ve done with the new, 3-year Golden Rule Warranty.” As with other Golden Rule Warranties, the transmission must be

warranties, contact ATRA’s Member Services and request the new Golden Rule Warranty forms. These forms no longer limit the 3-year warranty to GM, Ford, or Chrysler transmissions; nor are they restricted to transmissions less than 10 years old. For more details, visit ATRA’s web site http://members.atra. com.. com The new 3-year Golden Rule Warranty: One more way that we’re proving every day that ATRA really is  your  Association.

ATRA’s Ron Brattin Brings SEO to ATRA Members’ Web Sites

Ron Brattin

There’s little doubt that the internet is quickly replacing the Yellow Pages when consumers shop for services. So it should come as no surprise that ATRA is working to help its Members take full advantage of internet marketing. One of the most important con-

tweaks keywords and content to help you achieve the highest ranking possible. Higher ranking is a lot like placement in the Yellow Pages: That’s why you’ll find so many companies with names such as “AAAA Transmissions”; not very creative, but it got them placed

siderations for your internet presence is SEO: Search Engine Optimization. SEO determines your placement in search engines, such as Google and Yahoo: The higher your placement, the more effective your internet marketing will be. ATRA’s Ron Brattin recently earned his certificate in Search Engine Optimization and Internet Marketing through Web CEO: a leader in internet marketing strategies. “Ron put a lot of effort into this th is certification, and we’re really proud of the work he’s accomplished,” says ATRA CEO Dennis Madden. “The results from his optimization techniques are impressive: we’re seeing instant leaps

ahead of everyone else. And higher  placement equals equals more calls.  Naturally ATRA TRA’s ’s SEO service is available exclusively to ATRA Members. If your site is hosted through ATRA, Ron can make the tweaks directly, to improve your site’s ranking immediately. Not hosted through ATRA? That’s okay: Ron can still evaluate your site and make recommendations. To take advantage of ATRA’s SEO service, call Ron at 1-805-604-2020. Make sure you have your site URL and  passwords available for him to access your site. SEO is the next step to help you market your shop, and it’s just one

rebuilt to ATRA’s minimum requirement, and usage standards still apply. To begin offering these new, 3-year

in search engine placement.” Using exclusive analytical software, Ron examines your site and

more way that ATRA is here to help make your shop more competitive… and more profitable.

GEARS May/June 2011

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by Dennis Madden members.atra.com www.atra.com

Y

ou just acquired a few longtime transmission shops in the area and want to let the town know. What do you do? Well, if you’re Rapid Transmission in the San Diego area, you throw a Grand Reopening Bash, and invite the whole town! Rapid Transmissions has been in operation for over 40 years. It was recently acquired by Jim Alexander, and he relocated two of its stores to newer, larger accommodations. So they wanted to reach out and introduce the community to the new owner and new stores with an open house get-together. They called all their suppliers and asked them to get involved: Transtar supplied the food; Natpro set up a  booth with examples of old and new technology; Southland Clutch brought their performance clutches. The San Diego Mustang Club was in attendance and brought their show cars, along with a local motorcycle club that brought 20-25 bikes. Mark Raines, operations director for Rapid Transmissions, explained: “It gave us a chance to get together with a lot of the people from the area and show them who we are and what we have to offer.” Deon Olmos O lmos from f rom ATRA ATRA’s ’s Member Services department came by with the “ATRA Blimp,” lent a hand, and spoke to folks about the benefits of dealing with an ATRA Member shop. “Deon was a huge help in making our event a success,” claims Mike.

So how did things go? “The response was fantastic,” says Mike. “We planned for 150 people, and over

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GEARS May/June 2011

 

200 showed up. Jim had to relight the grill and cook up more food!” We’ve been saying for years that the best way to get your name out there is through community involvement. And what a terrific way for Rapid Trans to make its mark in the neighborhood.

Dear Mr. Wiggins,

 I want to express our deepest  gratitude for your help and the services of ATRA. As you know from our conversation, my wife and I were on a long distance vacation with our boat in tow when our transmission when out in Placerville Ca. We had never been to Placerville, let alone know of anyone there to help us with  such a problem. Thankfully, we found your com-

distance to the hotel we landed at. Once we made contact with J&C  Automotive, their professionalism  put us right at ease. They provid provided ed  safe storage for our boat and had the ball rolling on the transmis sion right away away.. They are exactly the people and the type of shop you want to deal with at a time like that.  Although my wife and I had an extended vacation in Placerville, we

 pany through a friend and with one phone call had a referral to one of your certified shops in close

were able to enjoy the area and not  stress about our vehicle or who was working on it.

Thank you for your help, thanks  ATRA for the service, and thanks to  J&C Automotive for being part of  your group group.. Your phone numbers will travel with us from now on! Sincerely, Stephen Doiron Santa Barbara, CA

GEARS

May/June 2011

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 POWER INDUSTRY  INDUSTRY NEWS   NEWS   POWER

POWERTRAIN INDUSTRY  NEWS  NEWS

GEARS  does

not endorse new products but makes this new information available to readers. If you have a new product, please email the press release information with applicable digital photo or drawing to [email protected] or send by mail to GEARS   2400 Latigo Avenue, Oxnard, CA 93030.  

,

GM 6L80E, 6L90E Kits with Pistons from Precision

Precision International is pleased to announce the availability of overhaul kits with pistons (P/N KP33900J) for two GM transmissions: 6L80E: (MYC) 2006-09 Cadillac STS-V, XLR-V (4.4L), XLR (4.6L), Escalade/ESV/EXT (6.2L), XLR (4.6L), Corvette (6.0L,6.2L), GMC Sierra Denali, Yukon Denali /XL Denali (6.2L), Pontiac G8 GT (6.0L), Hummer H2/SUT (6.2). 6L90E: (MYD) 2007-09 Chevy Silverado HD, Suburban, GMC Sierra HD, Yukon XL (6.0L). Master and banner kits are also available: PI# KP3300J series is sold with and without pistons. For more information, visit Precision on line at www.TransmissionKits.com.

Dodge Takes theTrans! Win with a Goerend  

Congratulations to Aron Nick and his team on winning the 1st Superstock Quick 16 Diesel Drag Race in Bradenton, Florida, February 26, 2011. Aron’s truck was equipped with

Also congratulations to Ashley Black of Black’s Diesel of Adairsvill, Georgia (www.blacksdiesel.com), with a 5.9L Cummins diesel and a Goerend

Transtar’s representatives are very dedicated to providing exceptional service. For further details on Honda and Acura units or any driveline kit or com-

48RE transmission, who scored a 4th place finish with a time of 11.47 seconds. Both teams are proud to run Goerend transmissions in their Dodge trucks. Visit Goerend’s web site at www. goerend.com to view their extensive testing equipment. Or call Goerend Transmission at 563 778 2719. Shipping worldwide.

 ponent, customers should contact their Transtar representative or call (855) TRANSTAR.

Transtar Industries, Inc. is the Premier Provider of Honda and Acura Units

Mazda FN4A-EL (4F27E) and FS5A-EL (FNR5)

Illustration 1 Early Style B81789

Transtar Industries, Inc., the premier provider of world-class driveline solutions, is also the leading supplier of OE-quality Honda and Acura transmission units to the automotive aftermarket. “Honda units may be difficult to find in the Aftermarket today. At Transtar, we have coverage of the vast   majority of the Honda and Acura total offering,” said Jim Berry, Transtar’s Vice President of Marketing. Marketin g. “Transtar’s extensive inventory allows these units

Mazda has revised the reverse  bonded piston for the FN4A-EL/FS5AEL transmission. TransTec® item B81789 (OE FN11-

to be shipped next day to virtually every market in the United States. Whether you rebuild, repair, or replace, Transtar has solutions for every customer.” “Uncommon units can be particularly challenging to transmission rebuilders,” says Mark Russell, Director, Complete Transmission Solutions at Transtar. “We offer solutions for those hard-to-build units, like Hondas and Acuras. We have what our customers need, at a great value.” Remanufactured in the U.S. to the original OE specifications, every Transtar Complete Transmission Unit is fully tested using state-of-thestate-of-the-art art equipment and is backed by the Transtar Seal

19-5H0A) was originally a notched design on the clutch apply surface. The apply surface is now a continuous, one piece surface. This change produces a part that is considered a window-frame design, which creates more contact area with the clutch plates, achieving a uniform clamping load across the clutch plate surface. The new window frame design will retrofit and can be used in place of the previously notched design for both applications. When ordering part number B81789 you will receive the new design as stock is depleted on the old design.

Illustration 2 Late Style B81789

Reverse Bonded Piston

a Dodge 6.7L, and a 48RE Goerend transmission. He registered a time of 10.90 seconds.

of Quality. Units are updated with the latest pieces and fittings and Transtar’s 36-month/100,000 mile premium warranty.

For more, visit TransTec on line at www.TransTec.com.

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GEARS May/June 2011

 

Mike Davidson Joins Elite as Business Development Coach Elite Worldwide has announced that Mike Davidson, an award-winning shop owner, has joined the company as its newest business development coach. In his new role, Davidson will use his years of experience as a shop owner in Little Rock, Arkansas, and the information he’s attained while serving on numerous industry boards and panels, to help shop owners throughout the U.S. build more profitable businesses. In addition to owning and operating one of the most successful auto repair shops in the U.S., Davidson is a graduate of the Automotive Management Institute, was the recipient of Arkansas’s NAPA Technician of the Year Award for seven consecutive years, and is a winner of the coveted Better Business Bureau Torch Award for Marketplace Ethics. Davidson has an affinity for helping others, and currently does so by  providing viewers with car care tips in local CBS segments. “Elite is always looking for business development coaches who not only have a history of success as shop owners, but who have a genuine commitment to ethics as well. For an individual like Mike Davidson to join our team, who not only runs one of top shops in the country, but who has won the Torch Award for Marketplace Ethics, is an absolute honor,” said Bob

the PCS to do one of two things: 1. Send more AFL feed pressure to the balance side, resulting in higher line pressures. This sets codes and makes line pressure unstable when trying to elevate AFL pressures. Or… 2. Leak so badly that it won’t regulate anything, causing line pressure to elevate to the point of damaging

The valve kit is quick and easy to install without purchasing extra tools, reamers, or costly replacement valves and sleeves. For more information or to locate your closest distributor, visit www. superiortransmission.com.

components. Either way, the leak creates a vicious cycle as it tries to compensate for itself. To correct this, Superior offers its K098 AFL valve fix. This newly designed AFL valve-and-spring combo, along with a simple cup plug, will stop the leak. And since the valve’s “Superior” design spreads the load across the entire rear casting, it’s a long term, Simple Solution™, sure to stop wear and leaks in their tracks.

for Non-Lockupby Dacco Transmissions,

Figure 1. Showing O.E. Design and Common Leak Area. (sets Code 1811)

 This is Why they set the Code 1811

Cooper, president of Elite Worldwide. Visit Elite Worldwide on line at www.EliteWorldwideStore.com, or call, toll free, at 1-800-204-3548.

Superior’s New 4T65E AFL Valve Fix for Code P1811 Here’s what happens: Low pressure from the AFL signal/balance oil leaks from valve bore wear at the small end of the balance side of the valve  bore in the channel plate casting. This wear causes low AFL balance pressure, which is becoming common in 4T65E units and is the main cause for code P1811.

Figure 2. Showing Superior’s Innovative Proprietary Design.

Lockup Converter  d    a n d  su r e a  M a k e su  t   c k ou t  ec c h e Direct drive performance with the drivability and efficency of a lock-up converter

 15  411 5  # 4  Boo t h #   n in B

• Applications for circle track, street performance, and restoration. • Patented lock-up converter for C6, THM 350/400, and Powerglide hydraulic transmissions. • Improves torque and fuel efficiencies with multi-clutch technology. • Greater selection of available stall speeds. • Lower inertia than stock converters.

DROP IN!!

• Improves transmission durability due to less slip and lower transmission temperature.

No transmission modications or calibration required!

Alma Products and Dacco have developed a drop-in lockup torque converter for any non-lockup transmission (THM-350 and 400, Powerglide,, 727, 904, C-4, C-6). Powerglide The unit requires no modifications to hydraulics, hardware, or wiring. Simply swap it the old non-lockup unit to the new one. It’s available in a 10” diameter, and stall speeds range from 1800-5000 RPM. Industrial testing has yielded 15% improvement in fuel economy. In development for 3 years, it’s  perfect for oval track and street/strip muscle cars. The result is better fuel economy, more efficiency (more power to the wheels), lower transmission temperatures, and decreased crank thrust. In the past, a high stall torque converter would have been too busy for street applications. This new unit allows a high stall for better acceleration and 100% cruising efficiency with lockup. It gives the car owner the option of numerically increasing axle ratio because of a locked converter, which means better acceleration and fuel economy. Lockup is a feature that will give automatic cars the same MPH in racing

When balance pressure leaks out the end of the valve/bore it doesn’t keep enough AFL balance oil against the AFL valve’s spring load. This causes

as stick shift cars. The converter is fully  balanced and has bearings at every interface.

GEARS May/June 2011

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 POWER INDUSTRY  INDUSTRY NEWS   NEWS   POWER

The engineer that patented the design (Pat #7770703) worked for Chrysler Powertrain engineering for 18 years. Production starts June 1, 2011. For more information contact Dacco Transmission Parts 866-6451452, or visit www.daccoinc.com.

Lista International Will Exhibitat ItsEastec 2011 Technician

Lista International Corporation will feature its Technician Series tool boxes at EASTEC 2011, May 17-19 at the Eastern States Exposition in West Springfield, Massachusetts, booth 5423. Lista International’s Technician Series toolboxes are the largest capacity, most durable boxes on the market, at an affordable price. Proudly made in the USA, they feature a rugged design  backed by a limited lifetime warranty warranty.. They come in five gloss, powder-coated colors, with two-tone color schemes available. All drawers are full extension with a 440-pound capacity. Drawers come standard with a mesh liner and include a divider and bin tool organization starter kit in the top drawer. Other drawers can  be equipped with a variety of divider options. Technician Series toolboxes are available in a choice of four styles: single bank, double bank, triple bank and two-bay. This enormous selection of footprints and drawer sizes means there’s a toolbox configuration to meet every need. Worktops transform the toolbox cabinet top into a productive work area. Toolboxes come standard with protective ribbed rubber mat, and are available with optional tops of stainless steel

fork truck bases, to stationary raised  bases with leveling. Visit Lista’s new web site devoted to technician toolboxes at www. ListaBox.com. ...Also from Lista International Redesigned Workbench System Lista International Corporation announces its newly redesigned auto-

num pans from TCI turn the ordinary into the extraordinary. A black powdercoated finish and the ability to hold a larger fluid supply increases heat dissipation, dropping internal transmission temperature by 20º to 30º, extending transmission life. These pans are built from aircraftquality aluminum and feature added

motive workbench system. Specially designed for automotive service and repair, Lista’s automotive storage and workbench solutions can be easily configured to suit specific needs without custom cost. Lista automotive service bay solutions include storage cabinets, tool boxes, workbenches, and mobile carts. Tough, industrial-grade construction and materials are engineered to stand up to hard use and still look great, while giving technicians quick and easy access to tools, parts, and supplies.

fins for improved cooling, while a magnetic drainplug keeps loose metal from  being circulate circulated d through the transmission. A unique, O-ringed (where applicable) sealing surface protects against leaks. Pans include magnetic drain plugs, a 1/8” NPT port machined machined directdirectly into the pan, new stainless steel hardware, and Allen wrenches. For more information on MaxCool™ pans or to see other great TCI®  high performance drivetrain components, visit www.tciauto.com, or call toll free at 888-776-9824.

 JDS Worldwide Worldwide of Miami to Open in New Location!

Rather than being limited to offthe-shelf products, Lista offers versatile, customized solutions that optimize the efficiency and productivity of service

After 20 years of experience and knowledge of the industry gave way to the creation of JDS Worldwide in 2004, a surge of consumer loyalty and confidence has allowed JDS Worldwide to once again expand to meet the demands that its customers have come to expect.

operations. The company customizes high-density storage and timesaving workspace solutions to bring consistent appearance, efficiency, and space usage to every cubic inch of available space in a dealership. For more information, visit Lista on line at www.listaintl.com.

TCI® Max-Cool™ Deep Aluminum Pans

JDS Worldwide will be moving to a new location in the heart of the commercial district of Miami. With a new warehouse providing more than twice its previous capacity, JDS is poised to  provide better better access access to both its existing customers and new clients. “Our new location is an excellent venue, which will allow for a

over wood core, stainless steel cover, or  butcher block. The toolboxes feature base options ranging from mobile casters, to fixed-

Premium cast, high-quality Max-Cool™ deep alumi-

74

larger inventory, giving our customers greater access to our products and our company,” said Joe De Santino, president of JDS Worldwide. “As both our

GEARS May/June 2011

 

international and domestic client bases continue to grow, we found that, to continue to deliver the level of quality and performance our customers have come to expect, this relocation was a necessity.” For more information please visit www.jdsworlwide.com.

 JASPER Offers GM Remanufactured 6-Speed Transmissions





rected. Dynamometer testing of domestic automatic transmissions simulates in-vehicle operation to assure trouble-free product results. An available Premium Service Plan offers customers even greater value.

Each transmission is covered by JASPER’s 3-year/100,000 mile nationwide transferable parts and labor warranty. Full warranty disclosure is available on our web site or upon request. For more information on the GM 6L80/90E and JASPER’s complete line of remanufactured transmissions,  please call 800-827-7455, or log onto www.jasperengines.com.

Precision Introduces  JF011E Overhaul Kit Jasper Engines & Transmissions, the nation’s leader in remanufactured  products, has added the GM 6L80 and 6L90E 6-speed transmissions to its remanufactured lineup, and are available for these 2007-2009 vehicles: Chevrolet Yukon Denali, Avalanche and Suburban GMC Sierra Denali Cadillac Escalade Chevrolet/GMC C/K 15003500 pickups These transmissions are unique in that the transmission control module (TCM) is inside the transmission.

Precision International has intro-

“These control modules are vehicle identification number (VIN) specific and must be reprogrammed accordingly,” says James Corbin, JASPER quality systems and new product development manager. “JASPER will ship these units already programmed per the vehicle VIN from the factory.” Every JASPER remanufactured transmission is subjected to strict, highquality processes: Disassembly, meticulous inspection, and cleaning of components. All new and remanufactured  parts are carefully inspected for correct tolerances to assure

duced overhaul kits for JF011E transmissions. This unit is a belt-driven CVT for medium FWD vehicles, applicable for up to 2.5 liter class vehicles. Part num ber 73900GX covers years 2007-2010 used in: Jeep Compass, Patriot Dodge Caliber   Nissan  Nis san Serena Ser ena,, Bluebi Blu ebird rd Sylphy, Dualis  Nissan  Nis san Altima, Alt ima, Maxima, Max ima, Lafesta, X-Trail (2.5L)  Nissan Rogue, Sentra Renault Koleos Suzuki Kizashi, Landy Mitsubishi Outlander, Delica



• • •





For more information, visit www. transmissionkits.com.

Midwest Hard Parts Now Selling Wholesale

Midwest Hard Parts, Inc. has provided top quality transmission hard  parts to transmission shops for over 10 years. They’re proud to announce the opening of a wholesale division. Their goal is to offer the same top quality  parts to suppliers and transmission transmission parts stores at reduced prices, to allow for the supplier and store to make a reasonable markup and still be able to offer their customers a fair market price. Per customer request, MHPI offers custom packing and labeling. They guarantee 100% blind shipping using  plain boxes and going as far as to cut their name off the shipping label. Whether it’s foreign or domestic, MHPI prides itself on stocking hardto-find parts. So leave the hard, greasy work of teardown to them, and buy a clean, ready-to-pu ready-to-put-on-the-shelf t-on-the-shelf part. Contact Midwest Hard Parts at 1-877-799.4783 and request a copy of their Frequently Sold Parts price sheet.

Mustang Introduces New Universal Transmission Dyno.

• • •



• • • •

Mustang’s latest product innovation for automotiv automotivee transmission repair and remanufacturing professionals is MAE-LDU-40, a universal transmission dynamometer that represents the most advanced, next-generation dynamometer for testing light-duty automat-



dependability. JASPER’s research and product development ensures inherent OEM design problems are cor-

D5 Mitsubishi Galant Fortis, RVR. Master and Banner kits are also available.

ic passenger car and light truck inline and transverse transmissions. Mustang designed the new system to specifically address the short-com-



GEARS May/June 2011

75

 

 POWER INDUSTRY  INDUSTRY NEWS   NEWS   POWER

ings of the standard transmission dynos found in the market today. The result is a transmission dynamometer that is more easily adaptable, more accurate, more user-friendly, with a more flexible software and data acquisition package, and most importantly, is more sensible from an economic standpoint. The new LDU-40 universal trans-

sion strain-gauge-type load cells on each output PAU provide continuous feedback to the control loop, allowing for more precise load control and more accurate testing results. A 30-tooth speed encoder ensures a higher resolution speed signal, and therefore a more accurate gear ratio calculation.

mission dynamometer is a quantum leap forward from the outdated systems that once upon a time were considered state-of-the-art. Take your transmission testing to an unprecedented level of accuracy, efficiency and usability. Forget the hassles of using custom mounting plates and spacers to get a torque converter fitted just right. Mount and test transmissions faster and easier than ever before with a universal system so flexible, you can change setup configurations in a matter of minutes, with a single operator. Universal Hardware The MAE-LDU-40 dynamometer is by far the most easily adaptable test system on the market. Test a wide variety domestic and foreign rearwheel transmissions without the need to purchase countless custom mounting  plates. Our patented Universal Adapter Plate virtually eliminate the need to have expensive custom plates for each transmission you need to test – saving you both time and money and simplifying your testing operations. Mustang’s system easily adjusts

The LDU-40 also includes Mustang’s Transmission Control Module, The MAE-TCM, standard with every unit. The MAE-TCM gives you the ability to test a transmission using the correct frequency and duty cycle, which ensures that the transmissions are being tested exactly as they  perform in a vehicle. All this results in a more accurate dynamometer, so you can test with more confidence.

to fit any torque converter without the need for complicated spacers and bushing combinations, making it easier to center and mount more transmissions faster. Our rotating head stock also allows you to easily adapt and configure the test stand to test front wheel drive transverse transmissions, including Honda and Mitsubishi, and longitudinal 42LE transmissions such as the Chrysler A606. Our use of U-joint drive shafts simplifies set up and dramatically minimizes the chance of damaging rear seals due to misalignme misalignment nt issues. More Accurate Test Results

2-6 Clutch Bonded Apply Piston Low/Reverse Bonded Apply Clutch Piston

The kit includes genuine front and rear NOK oil seals along with exclusive Quantum™ brand teflon sealing rings and premium TransTec® branded valve  body paper. paper.  Aisin TR60-SN/ VW O9D O9D

Featured Components Part Pa rt Num Numbe berr De Desc scri ript ptio ion n

 

APPLICATION

1-2-3-4 Clutch Bonded Balance Piston

Molded ru rubber pa pan ga gasket

B37169

Front seal

B37170

Extension & adapter housing seal

3542

Sealing ring kit

Kit number 2554 is in stock and available for immediate delivery.   For more information, visit TransTec on line at www.TransTec. com.

TransTec Introduce TransTec Introduces s Pistons in Kits for GM 6L45/50, 6L80, 6L90 Corteco now offers overhaul kits with pistons for General Motors 6L45/50, 6L80 and 6L90 applications. TransTec®  brand kits 2509, 2565 and 2566 are on the shelf ready to be shipped to you today. The following pistons will be included in the new kits:

B33423

 

TransTec Introdu TransTec Introduces ces  Jatco JF011E / Nissan RE0F10A Kits TransTec is pleased to announce the availability of TransTec® overhaul kit 2557, which includes all necessary sealing components to rebuild the 2006-up JF011E/RE0F10A transmission.

4-5-6 Clutch Bonded Balance Piston 4-5-6 Clutch Bonded Apply Piston

You can still order kits without pistons. Those items are 2523 (6L45/50), 2508 (6L80) and 2530 (6L90). Contact your customer service representative to place an order today. For more information, visit TransTec on line at www.TransTec. com.

TransTec Introduce TransTec Introduces s Aisin TR60-SN/VW O9D TransTec is pleased to announce the availability of TransTec ® overhaul kit 2554, which covers the rear wheel

Featured Components P/N

Description

Year  

2557

Overhaul kit

06-up

B29002

Right axle seal

06-up

B29724

Left axle seal

06-up

B37134

Converter hu hub se seal

06-up

B36523

Duraprene pan gasket

06-up

3544

Sealing ring kit

06-up

TransTec® kit 2557 is in stock and available for immediate shipment. For more information, visit TransTec on line at www.TransTec.

The LDU-40 achieves the highest level of accuracy in the industry thanks to its high quality electronics package. Cradle-mounted PAUs and preci-

drive, 6-speed Aisin Warner TR60-SN transmission. This unit is most commonly used in the Volkswagen Touareg.

76

com.

GEARS May/June 2011

 

SHOPPER CLASSIFIED ADS ERIKSSON INDUSTRIES Division of Wentworth Engineering

1-800-388-4418  Authorized

Parts Distributor

•Remanufactured Units * DYNO TESTED* •5HP30, 5HP24, 5HP19, 5HP18, 4HP24, 4HP22, 4HP18, 4HP14 •Specializing in SAAB 900/9000 5SP, as well as T-37 A/T 

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Soft Parts / Friction Kits / Steel Kits / Repair Manuals

• Lifetime Fluids / Rebuild Kits / Valvebody Kits

1-800-388-4418 Fax: (860) 395-0047 www.erikssonindustries.com 146B Elm St., Old Saybrook, CT 06475

**COMPUTERS** Transmission Control Module Mo dule E CM & TC M Mitsubishi-Honda-Hyundai-GEO Kia-Mazda-Nissan-Suzuki-Toyota BOSCH ECM GM - Ford - Chrysler - Dodge Next Day Da y Air Shipping Available One Year Warranty Best Customer Service! Ford *GM * Chrysler off vehicle ECM reprogramming available

Heated Cooler Line Flusher 800-725-6499 417-725-6400

Transmission Dyno/CV Tester

888-217-4072 Autocomp Technologies, Technologies, Inc. 8515 N. Freeway, Houston, Texas

www.g-tec.com

GEARS May/June 2011

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SHOPPER CLASSIFIED ADS

 Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X GEARS  Shopper

3. Larger ads can be placed elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders. For information on Shopper advertising in GEARS , contact GEARS , 2400 Latigo Avenue, Oxnard, CA 93030, or call (805) 604-2000.

Equipment Manufacturing Corp.

BMW

Mercedes-Benz

Audi

Remanufactured to Perfection Hundreds of Transmissions in-stock. Immediate installation available. 2 year unlimited warranty. Dyno-tested. Remanufactured torque converter included.

Toll free 800 - 372 - TRANS

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1331 Rollins Road • Burlingame, CA 94010 tel 650 - 348 348 - 3990 fax 650 - 348 - 3019

www.equipmentmanufacturing.com

 

RatioTek™

Valve Body Kits Easy to Install - Low Cost - Great Results

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RT-4L60E Fix Code 1870 Fast  Adjust 1-2 shift firmness without removing VB.

RT-E4OD/4R Kit fits E40D and 4R100

 

CORES CORES  We’ve Got Yours! With over 150,000 transmission, engine, and internal part cores on the shelf, we have the cores you need – ready to ship today!

Las Vegas, NV

3 High Tech Regulator Valves.  Adjust shift firmness. firmness.

RT-4L60E-HD RT-700R4 RT-700R4-HD RT-AX4S RT-4F50N RT-A750E RT-A750E-HD RT-A761E RT-A761E-HD

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RT-4ATAXLE RT-4ATAXLE-HD

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Also 5th Edition Ratiotek software now shipping!!

aamidwestcores.com

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GEARS May/June 2011

 

WE HAVE WHAT YOU NEED

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SHOPPER CLASSIFIED ADS

 Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X GEARS  Shopper

3. Larger ads can be placed elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders. For information on Shopper advertising in GEARS , contact GEARS , 2400 Latigo Avenue, Oxnard, CA 93030, or call (805) 604-2000.

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80

GEARS May/June 2011

 

 WE STOCK  VT25E,6L80E,6R60E,5R110W    USED & REBUILT PARTS We offer a complete machine shop for ALL of your rebuilding needs! • • • •

USED, NEW  AND REBUILT  FOREIGN  AND DOMESTIC   AND ND WHOLESALE  RETAIL  A ONE CALL CALL DOES IT ALL! 

800 00-461-5396 -461-5396

Rostra Performance Class linear solenoids outperform and cost less than their OE counterparts! To find out more  visit:

 Transmission  T ransmission.com .com

GEARS May/June 2011

81

 

SHOPPER  CLASSIFIED SHOPPER

May/June 2011

GEARS  classified  classified

advertising cost $95.00 for up to 50 words for a one time insertion. ATRA members are eligible to receive up to three (3) FREE classified (per 9 issues). Members wishing to place ads once their three FREE ads have been placed may do so at the cost listed above.  Ads exceeding the maximum word count will cost $1.50 for each additional word (not including phone number and address). advertisements advertiseme nts in GEARS  annually   annually

SALES SEMINAR

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SAVE  TIME  and  Money  Quickly  disassemble & assemble solenoids  For  the  following  following 5 and  6 speed  units: 

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Transmission Sales ■ Transmission Shop Advertising ■ Transmission Shop Management

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TSM.webex.com FOR SALE: Colorado Springs Automotive/Transmission Shop For Sale In business 25 plus years. Large commercial referral base, excellent reputation and name recognition. Well trained certied staff in place. Includes Real Estate. Owner retiring. Adjusted Prot $84,000+ Char lie Jones, FBB, Ltd., 800-395-7653, BUSINESS

www.fbb.com. California – You need to take a look at this one! 40 years of excellent business trans mission & general automotive service. Same great location, central California, this is not your ordinary shop. Large building with latest equipment, owner ready to retire. Contact (209) 6027250. ATRA Mbr  BUSINESS FOR SALE:

HELP WANTED: 

Experienced Technicians, Rebuilders, R &R, Diagnostic Technicians and Service Writers. Minimum of three years experience references a must and work history and cer-

tications. Topand pay,amedical insurance, paid vacation 5 day work week. Located in the center of the Texas Hill

WANTED: Portland, OR – Torque Converter Rebuilder – Must have a minimum of three years experience in all phases of converter, rebuilding, spline replacement, clutch bonding, hub replacement, nal assembly and general machine skills. Must be clean cut and have good references. Pay DOE, benets include va cation, holidays and medical. For more information please call Dave at Portland Torque (800) 640-0970 or email: [email protected]. ATRA Mbr  HELP

Register:

Bosch Pushbelts CVT belts & Luk CVT chains Contact:

[email protected] +31 13 521 7448

HELP WANTED: Regional HELP WANTED: 

Technical Director - Transmission remanufacturer is in need of an experienced technical expert to lead its remanufacturing operations in remanufacturing standards and quality control processes. This position requires vast experience in late model automatic transmissions, excellent communication skills (verbal and written), leadership abilities, and a drive for high quality products in a production environment. Excellent compensation package, based on experience. Full benets and relocation allowance. Please email your resume to b4ever [email protected]. Would you like to join the team of a growing transmission HELP WANTED:

shop in Northern NJ?and Weoutside are seeking rebuilders, installers, sales help for a 5 day work week. Please for-

Sales People – Large Midwest remanufacturer of automatic transmission components in need of aggressive sales people. Sales Territory includes the Northeast, Southeast, Midwest, Central and Southwest regions. Product lines include remanufactured torque converters, hard parts both used and remanufactured and new and complete transmissions. Knowledge in our product lines a must. All applicants held in the strictest condence. Send resume to: jshawaluk@remani [email protected]. ndustries.com.   ATRA Mbr  HELP WANTED: 

Transmission shop looking for Sales Manger, Rebuilders and R&R Techs. Contact: (805) 2361114.

Country. Please e-mail resume to [email protected] a1m@classi c.net or mail to Personnel Dept., P. O. Box 2339, Kerrville, Tx. 78029-2339. ATRA Mbr 

ward your work experience and history along with salary requirements to x [email protected]. All replies kept condential. ATRA Mbr  

82

GEARS May/June 2011

 

2011 ATRA Technical Seminars LOCATIONS 5/14/11 5/21/11 6/4/11 8/13/11 8/20/11 9/10/11 9/17/11 10/1/11 10/8/11 11/5/11

Denver, CO  Des Mo Moines, IA  IA  Vancouver, BC  Albuquerque, NM  NM  Cincinnati, OH  Atlanta, GA  Billings, MT  Chicago, IL  Portland, OR  Baltimore, MD  MD 

TRANSMISSION OVERVIEW  GM:

CHRYSLER:

LCT 1000 4L60/65/70E 4T65E 4L30E 6L80 4L65E 4L80E 4T40/45E

41TE 545RFE 45RFE 42RLE 42-46RE IMPORT:

RE5R05A   All Hondas  AW55-50SN  AW55-50S N

FORD:

 AWF 21B 6F50  AX4N 5R55N/W/S

Register Today!

Registration Costs:

Prepaid, preregistered ATRA members $149 Prepaid, preregistered non-A non-ATRA TRA members $189 On-site $220with every four paid. One registration free registration

Check http://members.atra.com for more dates and locations to come!

800.428.8489 • http://members.atra.com

Subscribe Today! Grab Your GEARS Now!

X

I want my very own subscription GEARS.

to the next 9 issues of

Name___________________________________________ 

 Address_________  Address__ ______________ _______________ _______________ _______________ __________  __ 

City_____________________________________________________ 

State_____________________________ Zip___________________ 

Phone___________________________________________________ 

Signature________________________________________________ 

Please enclose check or money order in U.S. funds and send to:

GEARS  •  •

24 00 LATIGO AVENUE 2400 AVENUE • OXNARD, CALIFORNIA 93030 or call: (805)604-2000 U.S. $30 ~ Canada $45 ~ Other Areas $65

GEARS May/June 2011

83

 

 AD DVERTISERS  A Name

Page

Name

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 A.T.R.A. .................................................  A.T.R.A. ............................. ........................................ ........................ .... 40, 61   http://members.atra.com

Mustang Advanced Engineering................................... Engineering.......................................... ....... 25   www.mustangdyne.com

BorgWarner Automotive ......................................................33   www.borgwarner.com Certified Transmission .........................................................31   www.certifiedtransmissions.com Dacco Transmis Transmission sion Parts...................... Parts.......................................... ............................. ......... 11   www.daccoinc.com ETE Reman .........................................................................17   www.enginetrans.com EVT Parts ............................................................................57   www.evtparts.com Florida Torque Torque Converter Corp. .................. ...................................... ......................... ..... 67   www.floridatorqueconverters.com Ford Customer Service Division.................... ........................................ ...................... .. 13

Precision European Inc .............................................Rider, 83   www.PEIus.com Precision International International .................... ........................................ ..................................... ................. 29   www.transmissionkits.com Raybestos Powertrain ...........................................................3   www.raybestospowertrain.com Seal Aftermarket Products............................ Products................................................ ....................... ... 39   www.sealaftermarketproducts.com Slauson Transmission Transmission Parts.................. ...................................... .............................. .......... 59   www.slauson.com Sonnax Industries.................... ........................................ ........................................ ...................... .. IFC   www.sonnax.com SuperFlow Technologies Technologies Group ................... ....................................... ....................... ... 67   www.superflow.com Superior Transmission Parts ...............................................23   www.superior-transmission.com TCI Automotive ....................................................................63   www.tciauto.com Transmission Specialties .....................................................37   www.transmission-specialties.com Transtar Industries, Industries, Inc. ................... ....................................... ...................................... .................. 9   www.transtar1.com TransTec By CORTECO......................................................27 CORTECO......................................................27   www.transtec.com VBX - ValveBody Xpress, Inc. .............................................36   www.valvebodyxpress.com Whatever It Takes Takes Transmission Parts, Inc. .................... .......................... ...... 5   www.wittrans.com

 G-Cor www.fordparts.com Automotive Corp ................... Automotive ....................................... .................................... ................ 35   www.g-corautomotive.com GEARS   Magazine ..............................................................68   www.gearsmagazine.com H G M Auto Electronics Inc. ................................................66   www.compushift.com Jasper Engines & Transmissions Transmissions ................... ...................................... ................... IBC   www.jasperengines.com Kuhle ...................................................................................66   www.kuhleus.com Life Automotive Products Inc................... ...................................... .............................. .......... 7   www.smartblend.com Lubegard® By International Lubricants, Inc. .................. .................... OBC   www.lubegard.com

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 ATR  AT R A Su Supp ppll ie ier r Me Memb mber ers s Reserve your free table top display for the  ATRA  ATR A 201 2011 1 tec technic hnical al semi seminar nar ser series ies tod today! ay!

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Call (805) 604-2018 See ATRA Seminar Schedule page 83. GEARS May/June 2011

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