TM

TM

Diagnostics • eleCtroniCs
Computer • DiagnostiCs Electronics • reprogramming
Reprogramming

TCRA and ATRA,

A Strategic Alliance

Ford 6F50N
TCRA Rebuilding
and ATRA,
Techniques
A Strategic Alliance
Mercedes
Ford 722.9 Techniques
6F50N Rebuilding Preliminary
Information
Mercedes 722.9 Preliminary Information MARCH
MARCH2009
2009
 4R/5R44E = Trouble. Sonnax = Solutions!
4R/5R55E 8 7
10
11
9
1
A.

B.
C. Note: Sonnax 37947-EZ contains
D. many of these solutions in one
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PROBLEM SOLUTION
EPC & Engagement Control Kit
• Poor shift quality
• Delayed forward or no reverse
1 37947-11K
F37947-TL11 Tool Kit Required
A.

B. C. D.

• Low TCC apply pressure TCC Regulator Valve Spring Kit

• TCC slip code, P0741 2 37947-46K

• Scratched OEM valve Standard TCC Regulator Valve

• Converter apply issues 3 37947-38

• No 4th gear 4R Oversized Coast Clutch Valve Kit 37947-33K

• No 2nd or 5th gear 5R 4 37947-TL33 Tool Kit Required

• Converter apply issues TCC Regulator Sleeve Kit 37947-09K

• High TCC slip RPM 5 37947-TL9 Tool Kit Required

• No TCC apply TCC Modulator Valve Sleeve Kit 37947-07K

• Code P1741 6 37947-TL5 Tool Kit Required

• Flare upshifts, Low EPC pressure EPC & TCC Relief Valve Kit 37947-40K
• TCC slips, P0741 7 37947-TL40 Tool Kit Required

• Loss of 3rd & 4th gear, Hot End Plug Kit 37947-13K
• Erratic shifting 8
• Delayed engagement Pressure Regulator Sleeve Kit 37947-05K
• High or low line pressure 9 37947-TL5 Tool Kit Required

• Low baseline pressure “Elevated Pressure” Main PR Springs 56947-17

10
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• Soft shifts Boost Valve & Sleeve Kits 37947-01K
• Delayed reverse 11 Increased Ratio
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products is available at Fax: 802-463-4059
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Automatic Drive • P.O. Box 440 • Bellows Falls, VT 05101-0440 USA

©2009 Sonnax Industries, Inc.

sonnax plcd ifc.indd 2 2/11/09 10:59:18 AM

GEARS Computer • Diagnostics • Electronics • Reprogramming

March 2009
PHONE (805) 604-2000 FAX (805) 604-2006
TABLE OF CONTENTS

Chief Executive Officer Dennis Madden

Managing Editor Rodger Bland
Technical Director Lance Wiggins Ford 6F50N Rebuilding Techniques Mercedes 722.9 Preliminary Chrysler’s New All-wheel Drive
Page 16 Information, Page 30 System, Page 38
Advertising Frank Pasley
Senior Designer Jeanette Troub

Contributing Editors Steve Bodofsky SPECIAL INTEREST & TECHNICAL

Martin Brooks Mark Mustard
Paul Mathewson Thom Tschetter
4 TCRA and ATRA, A Strategic Alliance
ATRA Technical Staff Bill Brayton
Mike Brown Steve Garrett
— by Joe Rivera and Bill Brayton
Pete Huscher Jon Rodriguez 16 Ford 6F50N Rebuilding Techniques — by Lance Wiggins
Randall Schroeder Dave Skora
Mike Souza 26 How Much? There’s More to It than You Think
— by Thom Tschetter
Director of Membership & IT Svc Kelly Hilmer
Seminars & Convention Manager Vanessa Velasquez
28 That Converter You Just Did!
Bookstore Manager Shaun Velasquez — by Martin Brooks
30 Mercedes 722.9 Preliminary Information, Part 1
— by Mike Souza
The views expressed in this publication should not necessarily be interpreted as
the official policy of the Automatic Transmission Rebuilders Association (ATRA). 36 Writing Your Operations Manual: How I Run My Business
Publication of product information or any advertising does not imply recommenda- — by Paul Mathewson
tion by ATRA.
GEARS™, a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030,
38 Keep Those Trannys Rolling: Chrysler’s New All-wheel Drive
is published for the betterment of the transmission industry and is distributed System — by Pete Huscher
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 transmis- 44 Fluid Matters: The Wrong ATF Can Ruin Your Rebuild
sion industry in the United States, Canada, ATRA Members in Mexico & Europe, — by Mark Mustard
and related automotive industry firms and individually. Send changes of address
to Gears in care of ATRA. Subscriptions are available by contacting Gears 46 Taking Advantage of Murphy’s Law: Answer the Phone
in care of ATRA.
All Day, Every Day — by Steve Bodofsky
Advertisers and advertising agencies assume full liability for all content of
advertisements printed and also assume full responsibility for any claims arising 48 Shop Profile: Santa Rosa Transmissions
therefrom against the publisher. The publisher reserves the unqualified right to
reject any advertising copy as it deems appropriate, with or without cause.
Sam Burrage; Owner — by Steve Bodofsky
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 profes-
sional person should be sought— from a Declaration of Principles jointly adopted
by a Committee of the American Bar Association and Committee of Publishers.
DEPARTMENTS
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
2 FROM THE CEO: Avoiding the Rat Hole
publishes. If you would like to submit an article to Gears, include background — by Dennis Madden
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. 52 ATRA News
57 Powertrain Industry News
Editorial and Business Offices 61 Shoppers and Classified
2400 Latigo Avenue, Oxnard CA 93030
Phone (805) 604-2000 68 List of Advertisers
Fax (805) 604-2006
www.gearsmagazine.com
www.atra.com
www.atraonline.com On the Cover: Joe Rivera and Bill Brayton
Publications Mail Agreement No. 40031403 present TCRA and ATRA,
Return Undeliverable Canadian Addresses to: A Strategic Alliance
Station A, PO Box 54, Windsor, ON N9A 6J5 Page 4
Email: [email protected]

Issue #137 Printed in U.S.A. Copyright ATRA 2009

 FROM THE CEO

Avoiding
the Rat Hole by Dennis Madden

A dvertising is critical for any

business. If you want people
to find you, you have to put
your name out there. But some types
of advertising are more effective than
want to fix it. The transmission flares
on the 2-3 shift? A valve body modi-
fication or an oversized servo and the
problem’s solved.
So when car counts are down, it’s
came in this week.
What you’re more likely looking at
is an accident of timing. A lot of shops
have been seeing more cars over the
last few months partly because of eco-
others. Put your money into the wrong only natural to want to fix it. And there nomic considerations, and partly due to
type and you might as well be stuffing are dozens of sales people out there just the winter, which has been severe for
it down a rat hole. waiting to tell you where to spend your most of the country. The increase may
That’s why we focused much of money to do that. have nothing to do with your new radio
last year’s What’s Working study on “Increase your ad budget,” they’ll spot, larger Yellow Pages ad, or updates
consumer buying habits: What they tell you. “Go with a larger ad in the to your web site.
look for in a repair shop and what Yellow Pages.” Or “let us show you Does that mean you can’t measure
kinds of advertising are most effective. how our Pay-Per-Click internet market- your advertising response? No, it just
Essentially we wanted to know how ing will drive more potential customers means you should take those measure-
consumers choose a transmission repair to your business.” ments with a grain of salt. A lot of
shop. Sure, you can buy more or big- different considerations factor into a
One thing we learned was that ger ads, and maybe you’ll see a slight consumer’s decision to choose your
consumers will usually ask for a rec- improvement here or there. But the shop over another. That’s one of the
ommendation from someone they trust vast majority of consumers are looking benefits of the What’s Working study:
when they have a transmission prob- for a more personal connection; they’re It eliminates those momentary surges
lem. The Yellow Pages ranked low looking for a shop they can trust. You’re or ebbs in the market, and lets you
from consumers who participated in not going to buy that trust with a larger discover what’s been working over the
the survey. phone book ad or web site banner. long term.
That’s why, when it comes to those That type of community-based Advertising is a critical part of
ads, size really doesn’t matter: Shops involvement isn’t necessarily easy. every business, and in bad times it’s
with a single, 1/8th page ad often do Many of us aren’t comfortable in social even more important. But unless you
better than shops with full page ads situations. And these programs often track your leads and are able to deter-
in several directories covering their don’t allow us to tackle the problem of mine the effectiveness of your pro-
region. bringing more cars in directly; they’re grams over time, you can’t determine
So what do consumers look for just about getting out there and min- if a new advertising plan really works.
when choosing a repair shop? Local gling… becoming part of the commu- And putting too much effort into that
activities and community-based adver- nity. But there’s little doubt that this new web site or radio spot may keep
tising provided the highest return. type of “friend in the business” attitude you from focusing on those commu-
Things such as sponsoring a local sports is what builds trust, and puts more cars nity-based activities that have proven
team, membership in local service in your bays over the long haul. successful, time after time.
organizations, ads in local newsletters Don’t be fooled by momentary Sure, those other ads are still
and school newspapers… activities that changes in the business climate. For important, and they must present the
bring you — the shop owner — closer example, many shops today are experi- proper image for your shop. But don’t
to the community and help generate encing a surge in business. It would be let them interfere with the ones that let
trust among potential customers. easy to attribute that increase to what- you build trust from the people in your
That may be easier said than done. ever advertising changes you made yes- community. Otherwise you could wind
Many of us have more of a technical terday. Put up a new web site last week? up falling down that rat hole.
mentality. If something is broken we It must be working, because more cars

2 GEARS March 2009

2FmCeo309.indd 2 2/16/09 11:06:54 AM

 Electronic Components Benefits Randy says: “I have discovered a new respect for every clutch, steel
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raybestos plcd.indd 3 2/11/09 11:01:49 AM

 TCRA & ATRA, A Strategic Alliance

& ATRA
A Strategic
Alliance

Joe Rivera and Bill Brayton

ATRA Technician
Owner, ProTorque

O
ne of the acknowledged truths model Honda. The transmission was and the TCC seems to be working fine.
about any business is that burnt up, so the transmission shop His scan tool doesn’t provide all that
certain alliances can improve rebuilt the transmission and installed a much information, but he can feel the
your profitability. rebuilt torque converter. converter clutch working, so he returns
This is by no means a unique situa- Everything seemed fine for the the car to the customer.
tion; it carries into just about every type first few weeks, but a month or two Within a few weeks it’s back with
of business. And nowhere is the need later the customer was back. The MIL the same P0740 code in memory.
for a strategic alliance more evident was lit, and the computer had code So how does the transmission shop
than the synergy created between the P0740 in memory, indicating a slipping deal with this type of problem? Many
transmission repair shop and the torque converter clutch. would simply call their torque con-
converter rebuilder. Close ties between So the transmission shop techni- verter rebuilder and order a second
these two businesses can reduce prob- cian does what anyone would do: He converter. And, unfortunately, many of
lems and comebacks, and improve checks the TCC operation. Sounds those shops would be seeing the car
profitability for both businesses. easy, doesn’t it? But nothing appears to back again in a few weeks.
Here’s an example of the benefits be wrong. He clears the code and drives The smarter transmission shop
of one such alliance: The car is a late- the car. The code doesn’t come back technician recognizes the need to work

4 GEARS March 2009

4-tcra309.indd 4 2/10/09 3:36:11 PM

 Two Cooperative Views
for Diagnosing a Honda
Converter Clutch Slip Code
Accord 4spd

Odyssey-Pilot 5spd

Accord-CRV 5spd

Figure 1: These are the valve assemblies that control TCC operation. Make sure they’re clean and working properly,
and the end plugs provide a good seal.

with the converter rebuilder. He’d know wouldn’t be particularly obvious. And of transmission issues that could affect
that a TCC slip can have a number while the converter itself could cause it too.
of possible causes, many of which this type of slip, there are also a number Let’s take a look at the different

GEARS March 2009 5

4-tcra309.indd 5 2/10/09 3:36:53 PM

 TCRA & ATRA, A Strategic Alliance

Honda Converter
Clutch Slip: The
Transmission
Technician’s View
by Bill Brayton

There are several issues you need

to consider when dealing with a P0740
TCC slip code on a Honda:
Diagnosis — If you happen to
have a dedicated Honda scan tool,
you can check the difference between
engine RPM and the mainshaft RPM.
When the converter clutch is fully
engaged, the speeds should indicate no
slip at all.
Unfortunately most scan tools
won’t provide that level of information.
If that’s the case, you’ll have to assume
the computer is seeing some level of
Figure 2: The black O-ring worked fine when the transmission was new, and none slip under certain conditions; you just
of the components were worn. But over time the combined component wear can won’t be able to check them directly.
allow the black O-ring to leak. Valve Body — You should have
disassembled and cleaned the valve
body during the rebuild, so hopefully
there are no problems there. While it’d
be nice to check the valve body again,
that’s easier said than done on a Honda.
Chances are you’re not going to want
to recheck the valve body until you’ve
decided to replace the torque converter,
since both jobs will require removing
the transmission from the vehicle.
If you do end up pulling the unit
again, pay particular attention to the
valves that control TCC operation. On
4-speed units and 5-speed Odyssey and
Pilot vehicles, these are:
• Lockup Shift Valve
• Lockup Timing Valve
• Lockup Control Valve
On 5-speed Accord and CRV vehi-
cles, you’ll only need to check these
two valves:
• Lockup Shift Valve
• Lockup Control Valve
Figures 1 provides an exploded
Figure 3: Always replace the black O-ring with the new, green O-ring. The green view of the valves that control TCC
O-ring is thicker, so it compensates for small amounts of wear in the different
operation. Make sure these valves are
components, providing a good seal.
clean and working freely. And check the
conditions that can cause this specific from the ATRA Technical Department; end caps; these caps tend to loosen and
problem, and look at them from both Joe Rivera from ProTorque offers the leak. You can order special replacement
points of view: the transmission shop converter rebuilder’s point of view. end caps from Sonnax that include an
and the converter rebuilder. O-ring to provide a more positive seal
The transmission technician’s point and eliminate end cap leaks.
of view will be provided by Bill Brayton

6 GEARS March 2009

4-tcra309.indd 6 2/10/09 3:37:17 PM

 >˜`Ê"ÛiÀ…>ՏÊ-ÞÃÌi“

verter
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 TCRA & ATRA, A Strategic Alliance

of your rebuild procedure. Or if every-

thing else checks out okay and code
P0740 returns, replace the solenoids.
Here are the solenoids that control
TCC operation:
4-Speed Units — CPC A and B
5-Speed Accord and CRV Vehicles
— CPC A
5-Speed Odyssey and Pilot Vehicles
— CPC C

Pump Gear to Converter Hub

Seal — Honda units have an O-ring
on the converter hub that seals the hub
to the inner pump gear. Originally this
was a black O-ring, with a diameter
of 1.440” (figure 2). And this O-ring
worked fine… when all the bushings
Figure 4: There are a number of different types of clutch facing available for
and shafts were new.
today’s converter clutches. The best way to make sure you’re using the right type But as the transmission compo-
of clutch material is to ask your supplier for the proper application. nents begin to wear, the original style
O-ring no longer seals the converter
charge oil properly. The problem is,
there’s no one item that’s really worn
enough to identify as being worn out;
and replacing everything isn’t a cost-
effective solution.
The better choice? Replace the
original O-ring with the new, green O-
ring (figure 3). The replacement O-ring
is 1.550” in diameter — 0.110” larger
than the original, so it provides a better
seal, even with the combined wear from
the older components.
Finally, once you’ve decided
everything else is okay and you need
to replace the torque converter, call
your converter rebuilder. Explain the
situation and let him know what you’ve
done so far. That way the rebuilder
knows what to look for, and will have
a better idea of what he needs to do to
help eliminate the TCC slip.
Figure 5: Never trust the temperature dial on your bonding press; check the tem-
perature directly using a digital pyrometer, to make sure the clutch is reaching
bond line temperature.
Honda Converter
Clutch Slip:
ATF — Improper transmission to correct TCC slips on a number of
fluid can be a likely source of all types vehicles.
The Converter
of transmission slips and chatters. The CPC Solenoids — Damaged or Rebuilder’s View
additives that alter Dexron for use in faulty solenoids are another likely
units requiring fluids with different fric- source of a TCC slip. Start by check- by Joe Rivera
tion characteristics work well, provided ing the solenoid resistance and opera-
you begin with a quality base fill. tion. Make sure the solenoid closes There are a number of issues that
If you used Dexron and an additive completely and flows freely when it’s can create a slipping problem in a
and are now experiencing a slip or chat- supposed to. Honda converter clutch:
ter, one of the first things you can try If the unit was overheated or had Clutch Material Compatibility
is to switch over to the factory fill; in severe metal contamination, you should — There are several different types
this case, Honda fluid. It’s been known replace the solenoids as a normal part of friction material available for the

8 GEARS March 2009

4-tcra309.indd 8 2/10/09 3:38:02 PM

C M Y CM MY CY CMY K
 TCRA & ATRA, A Strategic Alliance

But in most cases, the plain paper

clutch material won’t provide the nec-
essary holding power, temperature
capacity, or the proper coefficient of
friction to work with a pulse width
modulated converter clutch system.
These units usually require a high car-
bon clutch material to perform prop-
erly.
Most Honda transaxles use a
pulse width modulated control strat-
egy for their converter clutches. These
clutches have a certain level of slip
built into their control strategy. So it’s
important to use a converter clutch
material with a high carbon content
that can handle the additional heat
being generated.
If you aren’t sure which type of
clutch control system is used in the
vehicle you’re dealing with, ask the
transmission technician. He should be
able to tell you just by checking the
converter clutch solenoid resistance:
Figure 6: The vast array of springs and rivets act as a heat sink, which can carry the
PWM solenoids usually have a much
heat away from the bonding process. That’s one reason it’s so important to check the
clutch temperature directly. lower resistance than the older, on-off
solenoids.
Follow the Proper Bonding
Process — The converter clutch mate-
rial comes with the bonding adhesive
already applied. Bonding the clutch to
the piston involves a specific process
of heat, pressure and time, which is
provided by the clutch manufacturer.
That process isn’t a suggestion,
and close enough just plain isn’t. It’s
critical that you follow the bonding
process to the second… to the pound…
and to the degree. Each clutch manu-
facturer has its own requirements;
always contact them for the specific
specs and procedures for their bonding
adhesive.
• Check the pressure on your bond-
ing press to make sure it’s accurate,
and adjust it if necessary. Consider
adding a one-way check valve in
Figure 7: Another easy way to monitor the clutch bond line temperature is to use a the line feeding the piston to help
Tempilstik to mark the clutch piston. If the mark changes color, you can be sure the maintain a constant apply pres-
piston reached the temperature necessary for a proper bond. sure.
• Set a timer to make sure you’re
converter clutch; size and price are no you’re working on. following the bonding duration
longer the only considerations (figure Many of today’s vehicles no longer instructions; don’t guess about the
4). One of the first things you should do use a simple off-on converter clutch. time.
when addressing any type of converter These torque converter clutches are • Check the actual temperature
clutch performance problem is talk to now controlled by a pulse width modu- applied to the clutch material with
your clutch suppliers. Find out what lated (PWM) or duty cycle signal. This a digital pyrometer (figure 5); don’t
type of clutch material they recommend provides the computer with more con- just assume the adjustment dial is
for the specific vehicle and converter trol of the clutch apply feel. accurate. This is called bond line

10 GEARS March 2009

4-tcra309.indd 10 2/10/09 3:39:08 PM

superior plcd.indd 11 2/11/09 11:07:39 AM
 TCRA & ATRA, A Strategic Alliance

Figure 8: Your first step in checking converter clutch clearance is to measure the height from the clutch release stop
on the turbine hub to the bearing surface.

temperature; it’s the temperature at complete the bonding process. It should Check the Clutch Release
which the adhesive begins to flow still be close to the recommended tem- Clearance — The Honda converter
and bond to its contact surface. perature for bonding. clutch should have a clearance of about
Most adhesives will reach their You might want to test your bond- 0.015” to 0.035”. Any less and the
bond line temperature between ing press beforehand using an old clutch clutch could drag; any more and the
375ºF and 425ºF. piston. Install the piston assembly, and clutch may not apply all the way.
go through the bonding process. Then Here’s how to check the clutch
A few degrees too low… a few check the temperature immediately clearance on the Honda converter:
seconds too fast… a few pounds too after releasing the pressure: If the clutch 1. Measure the height from the clutch
little… and your clutch may not bond temperature is significantly lower than release stop on the turbine hub to
properly. This can allow the clutch to the manufacturer’s recommendation, the bearing surface (figure 8).
debond and fail during operation. adjust the temperature dial and try 2. Place the clutch into the front
The temperature check is the diffi- again. Keep performing this test until cover, and measure the height from
cult one to verify. First there’s the clutch you’re sure your bonding press is bring- the top of the clutch assembly
piston: Many, such as the Honda, have ing the clutch to bond line temperature. (where it rides on the clutch release
a very complex construction, including And recheck your press occasionally to stop on the turbine) to the bearing
various springs, rivets and other hard- make sure it’s working properly. surface (figure 9).
ware (figure 6). This hardware acts as a An alternate test would be to use 3. Subtract the first measurement
heat sink, drawing heat away from the a Tempilstik to mark the clutch piston from the second measurement.
clutch facing. So even if your bonding and check the bond temperature (fig-
fixture’s temperature is accurate, it’s ure 7). Tempilstik is a paint stick that So on the example unit, the first
possible the temperature will never get changes color when you exceed its measurement was 0.770”; the second
high enough to bond the facing to the rated temperature. There are dozens of was 0.755”.
clutch piston. Tempilstiks available in a wide range 0.770”
And some bonding fixtures don’t of temperatures, so you should be able –0.755”
provide you with access to the clutch to have one available for every clutch 0.015”
assembly during the bonding process, manufacturer’s temperature rating.
so you won’t be able to check the bond Tempilstiks are available through MSC • If the clearance is too low, you can
line temperature until you’re finished. Industrial Supply Company, at www1. machine the clutch mating surface
In that case, check the clutch pis- mscdirect.com. to increase it.
ton temperature immediately after you

12 GEARS March 2009

4-tcra309.indd 12 2/10/09 3:41:15 PM

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 TCRA & ATRA, A Strategic Alliance

• If the clearance is too high, you

can use a thicker clutch material.

Once you have the unit ready to

assemble, you can check your clear-
ance. To do so, you’ll need six shims:
three 0.015” shims and three 0.035”
shims.
Place the three thin shims on the
clutch (figures 10A & 10B), and slide
the converter assembly together. Then
check the clutch; it should rotate free-
ly. If it’s binding, even just a little, the
converter clutch doesn’t have enough
clearance.
Pull the unit back apart, and place Figure 9: Next, lay the clutch into place, and measure the height from the top of
the three thicker shims on the con- the clutch assembly (where it rides on the clutch release stop on the turbine)
verter clutch. Then slide the assembly to the bearing surface.
together again, and check the clutch.
This time it should bind; if not, the
converter clutch has too much clear-
ance.
IMPORTANT: Remove the shims
before welding the converter togeth-
er!
Once you have the clearance
adjusted properly, you’re ready to
assemble the clutch. And you shouldn’t
have any problems with its perfor-
mance.
While there are a number of
transmission issues that can create a
converter clutch slip, there are also
many ways to slip up in the converter
rebuilding process. The key is to fol-
low the procedures to the letter. If you
do that, you can virtually eliminate
those converter clutch slip codes on
Honda transaxles.
Two different approaches to a sin-
Figure 10A: You can check the converter clutch clearance directly by placing three shims
gle problem: While there are a number on the clutch, temporarily assembling the converter shell, and checking the clutch
of transmission issues that can create clearance. Just make sure you remove the shims before welding the clutch housing!
a converter clutch slip, there are also
many ways to slip up in the converter
rebuilding process. The key is to fol-
low the procedures to the letter, and
maintain open lines of communication
between the transmission rebuilder
and the converter rebuilder. If you do
that, you can virtually eliminate those
converter clutch slip codes on Honda
transaxles.

Figure 10B

14 GEARS March 2009

4-tcra309.indd 14 2/10/09 3:42:03 PM

 Precision parts without the
premium price.

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zf sales 309.indd 15 2/11/09 11:12:02 AM

 Ford 6F50N Rebuilding Techniques

Ford 6F50N
Rebuilding by Lance Wiggins

Techniques

Figure 1

F
Figure 2 Figure 3
or some rebuilders, every time is going to be cool. I can’t wait!” purchasing the special tools for the
they get a new unit in the shop Hopefully, you’re one of those guys 6F50N to remove and replace internal
— one they haven’t seen before who looks forward to something differ- clutch piston retaining snap rings, take
— they end up with that feeling in the ent, something new and exciting. For a look at the valve body, and see how to
pit of their gut that asks, “What am you, change is good! replace the ISS and OSS sensors.
I getting into?” Others look forward In this issue of Let’s Play Ball!
to the challenge; for them it’s, “This we’re going to cover how to get around

16 GEARS March 2009

16-lance309.indd 16 2/10/09 3:06:35 PM

 Figure 4 Figure 5

Once you have the

transmission torn down, it’s
time to start working on the
subassemblies.
The valve body has three main
bodies and one cover plate.

Disassembly Tips
The first thing to remove from
the unit is the valve body. The TCM is
part of the valve body, along with the
Transmission Range Sensor, the TSS
and the OSS connectors (figure 1).
Here’s how to remove the valve body
from the transmission:
• Remove the connectors from
the TCM.
• Remove the TCM from the
unit (figure 2).
• Remove the valve body bolts
from the valve body (figure
3).
• Remove the end cover and
start disassembling the
transmission.

Once you have the transmission

torn down, it’s time to start working on
the subassemblies.

Valve Body
The valve body has three main
bodies and one cover plate (figure 4).
To disassemble the valve body:
• Remove the cover plate and
main body casting.
• Remove the separator plate to
gain access to the checkballs
(figure 5).

GEARS March 2009 17

16-lance309.indd 17 2/10/09 3:07:47 PM

 Ford 6F50N Rebuilding Techniques

The checkballs are steel

(figure 6).
• Remove the valves, spring,
and related parts (figures 7
and 8).

As usual there are some regulator

valves you’ll need to pay close attention
to in both the main and lower valve
bodies. Refer to figures 7 and 8 for
descriptions.
Main Valve Body:
#6 Pressure Regulator Valve
#7 Direct Clutch Regulator Valve
#8 Intermediate Regulator Valve
#9 TCC Regulator Valve
Figure 6
#10 Low/Reverse and Overdrive

Figure 7

18 GEARS March 2009

16-lance309.indd 18 2/10/09 3:08:19 PM

 037 177 480 334A 880
530
378 047

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nput Shaft
IIn
n f
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Stator
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prec intl plcd.indd 21 2/11/09 11:15:11 AM
 Ford 6F50N Rebuilding Techniques

Figure 8

Regulator Valve shaft from a 4T60E • Use the deep socket as an

Lower Valve Body: • a large deep socket extension of the hub to be
#4 Solenoid Regulator Valve • a suitable press pressed down to remove the
ring (figures 11 and 12).
Overdrive Drum Here’s how to build your OD snap
The overdrive drum assembly also ring removal tool: Direct Drum
contains the input shaft. This makes • Use a cutting wheel to cut To remove and install the direct
it difficult to remove the piston from large slots out of the 4th clutch clutch piston return spring without
the clutch drum. For now, the only hub/shaft. breaking the tab, we used:
place to get those special tools is from • Place the ring gear on the • a low/reverse piston from
Ford/Rotunda. Since that can be both clutch retainer. an AW50-42LE or a 4L30E
time-consuming and expensive, we • Slide the 4th clutch hub down reverse clutch piston.
decided to use parts from around the onto the ring gear (figure 10).
shop to imitate the special tools needed
to disassemble and reassemble the
6F50N.
To remove the retaining snap ring
from the OD clutch piston return spring
assembly (figure 9), you can use:
• an A4LD/5R55E rear ring gear
(for the low/reverse planet)
• a worn out OD clutch hub/

Figure 9 Figure 10 Figure 11

20 GEARS March 2009

16-lance309.indd 20 2/10/09 3:08:51 PM

 Ford 6F50N Rebuilding Techniques

Figure 12 Figure 13

Figure 14 Figure 15

• a bar or 12” long, 3/8”

extension.
The 4L30E reverse piston will
have to be modified with a cutting
wheel to provide access to the snap
ring, but it’s the correct diameter to fit
the direct clutch piston. Or you can just
use the AW50-42LE low/reverse piston
(figure 13).
Place the drum in the press with
the bar or extension across the piston
to push the piston down evenly (figure
14).
CAUTION — Only press the direct
clutch cylinder down far enough to get
the snap ring out of its groove. Pressing
the cylinder down too far can break the
tab and the cylinder.

Intermediate Drum
To remove and install the
Figure 16
intermediate clutch retaining snap ring,
use: Use a cutting wheel or a torch distort as you compress the spring.
• an E40D/4R100 sun shell or (much faster) to cut large notches out Simply install the shell over the
RE5R05A sun shell (cut two of the sun shell (figure 15). These slots return spring assembly and use a press
slots opposite each other). will provide access to the snap ring. The or equivalent to press the shell down far
• a bar to use in the press. slots shouldn’t be any wider than 4”; enough to reach the snap ring (figure
any larger and the return springs may 16).

22 GEARS March 2009

16-lance309.indd 22 2/10/09 3:09:20 PM

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1evt parts.indd 5 11/18/08 8:42:45 AM

 Ford 6F50N Rebuilding Techniques

An inch or two away from

the end of the snap ring you
started installing, use the C
clamp to compress the return
spring.

Reverse Drum
By far this is the easiest drum
assembly to get into. To remove or
install the reverse clutch return spring,
all you’ll need is a pair of C-clamp
vice grips.
• Start one end of the retaining
snap into the groove.
• An inch or two away from
the end of the snap ring you
started installing, use the C
clamp to compress the return
spring (figure 17). Figure 17
• Use a screwdriver with a
twisting motion to secure the
snap ring in place.
• Move around the end cover
until the retaining ring is
completely seated in the
groove (figure 18).

TSS and OSS Replacement

You can replace the Turbine Shaft
Speed sensor (TSS) and Output Shaft
Speed sensor (OSS) with the transmis-
sion in the vehicle (figure 19). But it’s
much easier to replace the TSS than
the OSS. The TSS is located under the
Figure 18
valve body (figure 20). To replace the

Figure 19 Figure 20

24 GEARS March 2009

16-lance309.indd 24 2/10/09 3:09:57 PM

 Figure 21

Figure 22

This means the wiring runs inside the

transmission and snakes its way back to the Figure 23
valve body

TSS, remove the TCM and valve body, • Disconnect the harness. As for the rest of the rebuild, well,
then replace the TSS assembly. • Unbolt the OSS and remove it’s still just a transmission… no prob-
The OSS requires a little more it. lems there! And that’s the game!
effort; the OSS is located in the end Reinstalling the OSS is a bit dif-
cover (figure 21) and connects to the ferent. You’ll need to run a metal snake
valve body. This means the wiring runs or heavy gauge wire though the end
inside the transmission and snakes its cover and the case, and then attach the
way back to the valve body (figure 22). OSS connector to the snake and pull it
To replace the OSS: though (figure 23).
• Remove the pan.

GEARS March 2009 25

16-lance309.indd 25 2/10/09 3:10:36 PM

 How Much?
There’s More to It by Thom Tschetter

than You Think

Director of Marketing
Certified Transmission

M
ost of us think of market-
ing as sales and advertising.
Marketing is really much
broader than that. Advertising is only
one aspect of marketing, and it has just
one purpose – the creation of leads. the conclusion that when a caller asks happy to give you a price as
Advertising is not to create sales…it for a price, they are asking only part of soon as we’ve checked your
creates sales opportunities - leads. the question. What they really want to car. For your benefit, there’s
Before you invest a ton of money know is, “What do I have to do to find no charge for the check, it
in advertising, are you sure you’re out how much it will cost?” only takes about 20 minutes,
converting the leads your advertising Think about it. What would you and we’ll even do it while you
is generating? In the automotive repair say if a caller actually asked, “What wait. Is today good for you,
business, most leads come to us over do I have to do to find out how much or would tomorrow be bet-
the phone; so it’s imperative to use the it will cost to fix my transmission?” ter?”
best telephone procedures available. Does it make sense to ask a list of 4. When they agree to an appoint-
Even the worst telephone proce- questions about the car, what it’s doing, ment, get their name, number,
dures will get appointments. If that how long it’s been doing it, etc? Even vehicle details, and don’t for-
wasn’t true, some of you would have if you normally quote prices over the get to give them directions to
been out of business years ago. With phone, would you answer the question your shop.
that in mind, don’t read this article with by giving a price range or an estimate?
the attitude that what you’re doing is No…you would most likely tell them to Believe it or not, this simple tech-
working. I’m not arguing that point; bring the car in so you can take check it nique works. I don’t blame you if
I’m just asking you to be open to the and give them an estimate. you’re skeptical, but I know it works.
possibility that you can improve on So next time, give this a try. Plus it’s so short and simple that anyone
what your doing. Regardless of how the caller asks for in your shop can do it.
Whether using a memorized tele- a price, pretend they asked, “What do Next month I’ll expand more on
phone script or just “winging it”, price I have to do to find out how much this telephone procedure and share
shoppers can strike fear in the most it will cost to fix my transmission?” some of the best telephone finesse
seasoned professional. Over the years, Now, just answer that question and techniques, ever. Until then, give it a
some of the best trainers in the industry invite them in so you can check the car try…the nicest thing about this script
have taught us techniques and scripts to and give them an estimate. Here is a is that you haven’t risked a thing. If
avoid quoting prices over the phone. simple script that really works well. the caller balks, you can still fall back
It’s been said time and again that and use your current technique. But as
customers ask “How much?” only 1. “Thank you for calling you practice, you’ll find that you won’t
because they don’t know what else to Certified Transmission, how have to go back to the old procedure
ask. I don’t buy into that theory. In may I help you?” as often.
fact, I think it’s a silly belief. They ask 2. When they ask for a price, By the way, if you want a little
because they want to know the price you say, “A price? – you bet; coaching on this or anything related to
and frankly, the sooner the better. would you rather bring it in sales and marketing, feel free to send me
What reasonable person wouldn’t be now or later today so we can an email or give me a phone call. My
worried about the price? check it and give you an esti- email is Thom@CertifiedTransmission.
For years I have pondered the mate?” com and my phone number is 800-544-
price shopper dilemma. I’ve come to 3. If they ask again, say, “I’ll be 7520 ext 173.

26 GEARS March 2009

26-tschttr-ph.indd 26 2/10/09 3:28:41 PM

 Just Think - What if you had...
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■ 5,000 more transmissions &
transfer cases just a phone call
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Distributors have this
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Here’s what Ron Lingenfelter of

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“Even though we have a staff of

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Certified Transmission of Arizona ........................Tucson/Phoenix AZ........................................800-596-8878
Certified Transmission of Colorado......................Colorado Springs/Denver Metros ..................719-570-1539
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JC Parts City .........................................................St Louis, MO Metro........................................866-735-1960
J & M Transmission Service, Inc. ........................Sioux Falls, South Dakota ............................800-504-2050
Norfolk Transmission and Muffler ........................North-Central Nebraska ................................800-234-8726
RMP .......................................................................Philadelphia, PA Metro ..................................800-257-7418
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www.CertifiedTransmission.com

certifd plcd.indd 27 2/11/09 11:18:25 AM

 That Converter
You Just Did! by Martin Brooks
Aceomatic Transmission Services
Christchurch, New Zealand

Figure 1

T
he converter was from a ZF dering again. I decided I needed to get he would be able to fix the problem.
5HP19 with a captive clutch, the unit back and check it. There was no I was reluctant to allow this as he’s a
fitted to an Audi AWD. We’d evidence of any problem, so I suggest- good customer. So after asking around
overhauled the converter about a month ed he check the transmission carefully. and hearing that often the fault could
before and now my customer, who was a We reassembled the converter with new only be cured with a factory converter,
transmission rebuilder about 350 miles lining and extra care on the clearances. I offered to obtain a factory unit for
away, claimed the converter shuddered He installed it and reported that the him.
during the regulation phase. As always, shudder was once again gone. The factory unit arrived and was
my first question was, “What fluid are About a month later he called to fitted; vehicle drove well with no shud-
you using?” tell me that his customer was once der. About another month goes by and
“Dexron 3,” he replied. again complaining of a shudder. He the customer is back once again with
So naturally I suggested that he tried another valve body and was now the same complaint. I was out of ideas;
switch to either the factory fill or an sure it was the converter. He suggested the only way that I could help was to
equivalent. He did so and reported that that perhaps he should send the con- look at the car. That’s no problem for
the shudder was gone. verter to another rebuilder, because it us, since we’re also a transmission
About three weeks later he called appeared we weren’t having any luck, shop.
again to tell me the converter was shud- and the competitor assured him that

28 GEARS March 2009

28-mbrooks309.indd 28 2/10/09 3:24:34 PM

 The car arrived and sure enough, it
had one of the worst shudders I’ve ever
felt. We checked the obvious external
causes such as engine codes, etc., and
then removed the pan. This is where it
got interesting: The technician noticed
the fluid had a strange look to it. Not
pink or discoloured, but “just doesn’t
look right.”
At the last TCRA seminar there
was a brief mention of testing for water
using a drip coffee maker with a paper
filter (Figure 1). A drop of the fluid hit
the hot plate and it sizzled: a sure sign
of water (Figure 2 and 3).
Then we had a professional test
performed. It revealed the fluid had 2%
water contamination. It turned out that
Figure 2
the radiator was leaking coolant into the
fluid; not a lot, just enough to change just smokes the fluid
the frictional characteristic of the fluid. is okay.
Of course each time the fluid was Remember: the
changed the problem was gone until fluid can look good and
the contamination reached the critical still be contaminated.
level again. And this test won’t
We rebuilt the converter once identify all types of
again, with new converter clutch lin- contamination. It’s pos-
ing. And the transmission was rebuilt sible to have a coolant
again using new clutches, and the car’s leak that won’t show
radiator replaced. Several months have up with this “quick and
passed without any further problems. dirty” test. I strongly
The moral of the story? Think recommend that you
outside the box, don’t take anything invest in a commercial-
for granted, and remember this quick ly available test kit to
and easy test for water in the ATF. Just check for coolant con- Figure 3
put a drop on the hotplate of your cof- tamination. tomer and was paid for all the convert-
fee maker: If it sizzles and spits, it’s Of course the best part of this ers and the transmission job… as well
likely contaminated with water; if it whole story is that I retained my cus- as a radiator!

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610-485-9110 s Fax 610-485-9356 s www.transmission-specialties.com

GEARS March 2009 29

28-mbrooks309.indd 29 2/10/09 3:25:18 PM

 Mercedes 722.9 Preliminary Information, Part 1

Mercedes 722.9
Preliminary
Information, Part 1 by Mike Souza

T he Mercedes 722.9
transmission has been
around since the later
part of 2004, but there still
isn’t a lot written about it. The
722.9 can be found in these
Mercedes vehicles:
2004-06 – SL500

2005-up – CL500, E500,

S430, 500, SLK350,
55 AMG

2006-up – C230, 280, 350,

CLK350, CLS500, E350,
E63 AMG, R350, 500,
SLK280 • Earlier upshifts and later
downshifts
2007-up – CLK550, CLS550, • 37-47 MPH • Reverse gear 2 (2.231:1)
CL600, CLS63 AMG, E550, acceleration times are short-
E63 AMG, GL320, 450, ened by 23-28% (model The transmission will start in first
ML350, 500, ML63 AMG, dependant). gear if any of these conditions apply:
R63, and S550 • Fuel consumption is reduced • 1st gear is selected manually.
by up to 4%. • ¾-throttle to full-throttle
That’s a lot of vehicles! This 5th • Noise levels are reduced due acceleration from start.
generation transmission is the first 7- to lower engine speed in 5th, • Cold engine temperature (pre-
speed automatic produced by Mercedes 6th and 7th gear at constant catalytic warmup).
Benz. The Mercedes designation for vehicle speed.
this transmission is New Automatic • Flexible adaptation to vehicle Emergency Function
Gearbox 2 (NAG2) or 7G–Tronic. and engine. or Limp-Home Mode
Along with seven forward speeds this There are a variety of failsafe
unit also has two reverse gears ratios Variable Shift modes:
(similar to the 722.6) depending on Programming • If a solenoid doesn’t work the
whether it’s in Sport or Comfort mode. There are two basic shift programs affected gear is blocked. For
that can be varied by the customer example: if solenoid Y3/8y7
Shift Strategy (similar to the 722.6) using the S or C or the B3 clutch is defective,
Shift strategy improvements button on the Electronic Shifter Module you won’t have 1st, 7th or
include: (ESM): reverse in S mode.
• Computer reaction time is 0.1 1. S (Sport) • If a hydraulic fault prevents a
second shorter. • 1st gear starts gear from engaging, the previ-
• Downshifts are shortened by • Normal shift points ous gear will remain applied.
up to 0.2 seconds. • Reverse gear 1 (3.416:1) • If the computer defaults to
• Coasting downshifts are short- 2. C (Comfort) limp mode while driving,
ened by 0.4/2.5 seconds. • 2nd gear starts it’ll turn all solenoids off.

30 GEARS March 2009

30-mikeS309.indd 30 2/11/09 2:33:57 PM

 Figure 1
Solenoids that are normally transmission will be in 6th redirected to the B2/BR sole-
open will allow full pressure gear. After shifting to park, oil noid by emergency operation
to selected clutches and the pressure from K2 solenoid is valves, and the transmission

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30-mikeS309.indd 31 2/12/09 12:00:17 PM

 Mercedes 722.9 Preliminary Information, Part 1

Figure 2 Figure 3

Figure 4
will now provide reverse, and • B1 Brake Clutch Solenoid • Oil Control Float 2 (32)
2nd gear with the selector in (Y3/8y5) (normally open)
drive (figure 1). • B2 Brake Clutch Solenoid Fluid Level Float Function 2
(Y3/8y6) (normally closed) The extended length of the trans-
Electronic Control • B3 Brake Clutch Solenoid mission (41mm) allows oil to slosh
Components (Y3/8y7) (normally closed) forward during hard stops. To prevent
Here’s a diagram of the compo- • Torque Converter Lockup oil foaming from gears running in fluid,
nents that make up the electronic con- Solenoid (Y3/8y8) (normally Mercedes added a front float.
trol system (figure 2). closed)
• Transmission Control Module Three Speed Sensors
(Y3/8n4) (flash capable) Normally Closed: high current, high These components are built into
• Working Pressure Control pressure; no current, no pressure. the valve body assembly (figure 3):
Solenoid (Y3/8y1) (line/nor- Normally Open: no current, high pres- • Turbine RPM Sensor (Y3/8n1)
mally open) sure; high current, low pressure. (Front)
Normally open solenoids are used
• K1 Clutch Solenoid (Y3/8y2) • Internal RPM Sensor (Y3/8n2)
for limp mode with no current to the
(normally closed) (Center)
transmission.
• K2 Clutch Solenoid (Y3/8y3) • Output RPM Sensor (Y3/8n3)
(normally open) (Rear / Hall Effect)
• K3 Clutch Solenoid (Y3/8y4) Two Oil Floats • Selection Range Sensor
(normally open) • Oil Control Float 1 (31) (Y3/8s1)

32 GEARS March 2009

30-mikeS309.indd 32 2/12/09 11:00:22 AM

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 Mercedes 722.9 Preliminary Information, Part 1

Unlike the Lepelletier

geartrain, the 722.9
geartrain has the
sun gear fixed to the
K1 clutch assembly,
located in the front of
the unit (figure 6).
three clutch packs to provide seven
forward gear ranges and two reverse
ranges.
• 4 Multi-Disc Brakes
• 3 Multi-Disc Clutches
• No Sprag

Gear ratios are achieved with one

Ravigneaux and two simple planetary
assemblies shown in figure 5. Unlike
the Lepelletier geartrain, the 722.9
geartrain has the sun gear fixed to the
K1 clutch assembly, located in the front
of the unit (figure 6). The Ravigneaux
planetary assembly is also located in the
front section of the transmission (figure
7). There are two simple planets located
toward the back of the transmission,
one in front of the other (figure 8).

Fluid Type
The 722.9 uses a newly-developed,
suggested-use-only transmission fluid,
referred to as ATF 3353 (figure 9). It
Figure 5 promises a higher friction consistency,
thermal stability, and temperature rat-
Range Sensor Function / small ring gear). ing. ATF 3353 can also be used on
2. The center speed sensor (Y3/8n2) previous model 722.3/.4/.5/.6 transmis-
The Y3/8s1 range sensor is monitors the Ravigneaux carrier sions. This special ATF is available
built into the ECM ribbon cable, and speed (ring gear of rear planet). from Shell & Fuchs Europe oil sup-
can’t be replaced individually. It’s a 3. The rear speed sensor (Y3/8n3) pliers in 1 liter bottles under Mercedes
Permanent Magnetic Linear Contactless monitors the park pawl gear (excit- Benz part number A001 989 45 03 10.
Displacement (PLCD) sensor; it has a er ring/2 Hall Effect). No scheduled maintenance is
permanent magnet mounted to the man- required for the 722.9 (fill for life).
ual valve, which changes the magnetic The magnets for these sensors are In the next issue we’ll go into
field and output voltage as you move molded in a plastic ring and secured sequential shifting, powerflow, and
the selector. If the sensor signal doesn’t inside nonferrous flanges. some unusual features associated with
register properly with the computer, the Mercedes 722.9.
it’ll put the system into limp mode. Transmission Fluid
Temperature
Speed Sensor Function The transmission fluid temperature
The 722.9 uses three speed sen- sensor is built into the TCM, and isn’t
sors to monitor transmission operation replaceable separately.
(figure 4):
1. The front speed sensor (Y3/8n1) Clutch Components
monitors turbine speed (input shaft The 722.9 uses four brakes and

34 GEARS March 2009

30-mikeS309.indd 34 2/11/09 2:35:23 PM

 K1 Clutch
Assembly

Figure 6

Ravigneaux
Planetary Gears

Figure 7

Planetary
Assembly

Figure 8 Figure 9

GEARS March 2009 35

30-mikeS309.indd 35 2/11/09 2:35:50 PM

 Writing Your Operations Manual

How I Run My
Business by Paul Mathewson

I n the last edition of GEARS, we

began to discuss how you could
put an operations manual together
that you could hand over to someone
who had to replace you. In the closing
notes.
Keep it
handy to jot something down whenever
you think of something relevant to your
way of doing business. The notebook
• How the shop gets cleaned and
equipment maintained.

Stuff to Write Down

Believe it or not, you’re now orga-
paragraph I told you I’d make it easy needs to have at least 70 pages. Put nized to write your own, personalized
for you create your manual. I can do a heading on the first page that reads operations manual. It’ll reveal your
that because I’ve already done one for “What is a transmission shop?” Leave acquired wisdom that’s given rise to
our shop, so the organization of such a two blank pages and put a heading the success of your business. You don’t
manual is already done. I’ll provide a on the next that reads “Why am I in have to write an English essay on each
template for you, but you’ll need to fill the transmission business?” Two more of the 18 topics listed; you just have to
in the details. blank pages before you write “What I make notes, comments and observa-
This may surprise you, but you’re know about my competitors.” tions. At this point it doesn’t have to
already doing this. For example, every Keep going: Leave two blank be presentable. The various pages are
time you plan to be absent from the pages, then write sections for each of just for you to collect data that you’ll
shop you write notes to your employ- these headings: assemble later.
ees. If you’re going to be away for less • Where is our shop, what does it Start writing. I suggest you start
than a day you probably leave post-it look like, how is it equipped? with an easy one first like “Who we buy
notes for anyone who has to make a • What factors have led to our from, who we don’t, and why.” List all
decision for you until you get back. success in sales? the suppliers you use, including parts,
If you’re going on vacation, the post- • The future of my business, if I shop supplies, ATF, waste disposal,
it notes aren’t adequate, so you write could have it my way. towing, tools, maintenance services,
some things to remember about “how • The trade associations, col- uniforms and the like. Now explain
we do things here.” leges, AAA, etc., that think why you choose them and avoid oth-
But what if you’re going away, we’re cool. ers. That explanation reveals your real
never to return? In that case, what • How a typical trans job gets life experiences with each and justifies
you’re going to write is a homespun, processed through our shop. your choices.
amateur operations manual, and it’s just • Who works here and what I Go into detail as you write your
an extension of the same thing you’ve expect from each of them. notes. For example, “parts” may need
been doing when you left notes for your • How we price our work for to be broken down into soft parts, hard
staff. different kinds of jobs. parts, cores, torque converters, manual
So we’re talking about a collection • The minimum standards I trans parts, reman assemblies, cutouts,
of your thoughts built around one sim- insist on for work done here. etc.
ple theme: “How I Run My Business.” • How we warrant our work. Under “hard parts” you’ll probably
And remember, it’s about YOUR busi- • The forms and computer sys- have strong feelings about rejecting
ness… not anybody else’s. That means tems we use. sales pitches from junk suppliers so you
that you’ll explain not just what you • Advertising I like, and adver- need to state that, and, at the same time,
do at your shop but why you do it that tising I don’t like. refer your successor to hard part suppli-
way. You won’t be around to explain • How we generate business ers you trust.
anything later, so you have to do it now. from outside sales. “Soft parts” suppliers are plenti-
So let’s get started. • Who we buy from, who we ful, but your experience with quality,
don’t, and why. pricing and delivery will dictate which
Getting Started • The legal stuff: incorporation ones to use and which to use only for
I’d suggest you use a student note- papers, leases, contracts, tax back up.
book or a loose-leaf binder for your documents. Similarly, whose torque convert-

36 GEARS March 2009

36Mathwsn.indd 36 2/10/09 4:30:14 PM

 ers do you use and why? Do you R&R Writing to The Ignorant Next Month and Beyond
torque converters? How do you con- Remember, throughout this pro- As you can probably guess by now,
trol core returns? For this section, just cess you’re writing to someone who the heading pages in your notebook
imagine you’re writing to a new Parts may be completely ignorant of how to will develop into a table of contents for
Manager you’ve hired to do all your run your transmission shop. Heaven your finished product. But that’s a long
parts purchasing; then imagine you’ll forbid, but it may be your widow who’s way off yet. You have a lot of notations
never speak to him again — this is your offering your shop to a potential buyer to jot down under the 18 sections we
only communication! who’s never worked in the transmission discussed.
business before. So work away at the easy ones. In
Writing Incidentally She can’t show him the ropes. the next issue of GEARS, we’ll start
A lot of these ideas will occur to Hopefully she can provide him with probing at the question of “Why am I in
you as you’re working. That’s when your operations manual that spells out the transmission business?” You’ll need
you need to grab the notebook and how this profitable transmission shop to think hard about that subject, but I’ll
make an entry. If your notebook isn’t works. And you’re the only one who help you with that one, too.
nearby, write your thoughts on a post-it can download your brain into a printed
note and stick it into the notebook later. format.
Don’t worry about inserting things in
the right spot on the page; just jot them
down somewhere in the correct section
marked “Who we buy from, who we
don’t, and why.”
Okay, if you want to start on a
couple of other easy ones, I suggest
the next the topic to be “The minimum
standards I insist on for work done
here.” This subject surfaces every day
when you’re selling your work and
when you’re overseeing operations.
So, what does go into every auto-
Ready to Shift to a Better
matic overhaul at your shop? Do you Insurance Program?
replace the EPC in every electronic
unit? Do you use one particular man- Get into Gear with
ufacturer’s valve body updates in any
or all rebuilds? Is the converter always Heffernan Insurance Brokers.
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You need to use the same level of
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cases and anything else you work on.
Property/Tool Coverage Vision/Life
The object is to explain to a newcomer
how you like everything done. Auto Disability
Warranty policy and procedure is Workers Compensation HR Assistance
another easy one for you to write about.
So go to the section in your notebook
called “How we warrant our work.” Contact us today!
Describe the warranty provisions and
Property/Casualty Employee Benefits
the limits you offer for the various jobs
you do. Earl VanBuskirk Jani De La Rosa
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GEARS March 2009 37

36Mathwsn.indd 37 2/10/09 4:31:24 PM

 KEEP THOSE TRANNYS ROLLING
Chrysler’s New
All-wheel Drive by Pete Huscher

System
I n our last issue of Keep Those
Trannys Rolling, we took a brief
look at what’s new in four-
wheel drive systems and discussed
Borg Warner’s Interactive Torque
Management System (ITM 3e). In this
issue, we’re going to take a closer look
at the Interactive Torque Management
System available in various models of
the 2009 Chrysler 300, Dodge Magnum,
and Dodge Charger.
These vehicles use an electroni-
cally-controlled transfer case, which
eliminates the need for an electroni-
cally-controlled coupler at the rear dif-
ferential as was used in other applica-
tions.
This new ITM 3e system is made
up of two technologies: Active Transfer 2009 Chrysler 300
Case and Front Axle Disconnect (also
known as FAD). The system uses a
new design transfer case that auto-
matically connects and disconnects the
components that drive the front wheels.
The all-wheel drive system operation
is seamless. An indicator diagram is
located between the tachometer and
speedometer to show the driver which
wheels are receiving power (figures 1
and 2).

The Heart of
the ITM 3e System
The heart of the ITM 3e system
is the BorgWarner 44-40 transfer case
(figure 3). The Borg Warner 44-40
(BW44-40) transfer case allows torque
to be applied variably to the front axle, 2009 Dodge Magnum
and it has a fixed gear ratio. By allowing (crow hopping) that occurs with most bly within the transfer case (figure 4) to
variable torque application between the four-wheel drive transfer cases. vary the amount of torque applied to the
front and rear axles, this all-wheel drive Depending on conditions, the Drive front axle, while continuing to deliver
system can be driven on dry pavement Train Control Module (DTCM) will torque to the rear axle.
without the typical driveline wind-up modulate the electronic clutch assem- This BW44-40 transfer case uses

38 GEARS March 2009

38-pete309.indd 38 2/11/09 10:41:02 AM

 a special MOPAR transfer case lubri-
cant (p/n 68049954AA). The BW44-
40 transfer case contains an oil pump
to circulate gear lube throughout the
transfer case and provide clutch cool-
ing. The Drive Train Control Module
monitors the temperature of the transfer
case with a temperature sensor and is
capable of disengaging the all-wheel
drive system if transfer case tempera-
ture exceeds recommended limits.

Brains of the
ITM 3e System
The Drive Train Control Module
(DTCM) is the brains of this ITM 3e
all-wheel drive system. In the earlier
versions (2007 and 2008), the AWD
control module controlled the all-wheel Figure 1: Indicator displays rear wheel drive engaged
drive system and the electronically-
controlled coupler located in the rear
differential.
In the 2009 ITM 3e system, the
electronically controlled coupler
was eliminated, and the AWD mod-
ule has been replaced with a Drive
Train Control Module. The Drive Train
Control Module controls the electronic
transfer case, providing seamless all-
wheel drive operation when needed.
The DTCM communicates with the
PCM, TCM and ABS control module
over the CAN-C system and uses inputs
from each of these systems to control
the all-wheel drive system (figure 5).

Diagnosing the
ITM 3e System
Diagnosing the new ITM 3e all- Figure 2: Indicator displays all-wheel drive engaged
wheel drive system is pretty straightfor-
ward. Simply connect your scan tool to trol module indicating an out of range return control circuit open. Indicates
the DLC connector and check for codes tire revolution. Check the ABS control the DTCM has detected an open circuit
in the PCM, TCM and ABS control system for wheel speed sensor codes. in the AWD clutch power or ground cir-
module. Document all codes received Repair as needed. cuit. Check AWD clutch control circuit.
from each of these modules. C1456 — AWD clutch power Repair as needed.
Before starting your diagnosis, control circuit low. Indicates the DTCM C1464 — Front axle disconnect
correct any codes in the other modules. has detected low voltage in the AWD control circuit low. Indicates the DTCM
PCM, TCM and ABS problems can clutch power circuit. Check battery or has detected low voltage in the front
interfere with the all-wheel drive sys- system voltage. Check DTCM power axle disconnect circuit. Check DTCM
tem operation. After all the codes have and grounds. Check AWD clutch cir- power and grounds. Check front axle
been corrected in the other modules, cuit. Repair as needed. disconnect circuit. Repair as needed.
access the Drive Train Control Module C1457 — AWD clutch power C1465 — Front axle discon-
and retrieve any codes in memory. Here control circuit high. Indicates the DTCM nect control circuit high. Indicates the
are the codes you might find in the has detected high voltage in the AWD DTCM has detected high voltage in
Drive Train Control Module, and what clutch power feed circuit. Check bat- the front axle disconnect circuit. Check
those codes indicate: tery or system voltage. Check DTCM DTCM power and grounds. Check
C1078 — Tire revolution range power and grounds. Check AWD clutch front axle disconnect circuit. Repair as
performance. Indicates the DTCM has circuit. Repair as needed. needed.
received a message from the ABS con- C145D — AWD clutch power/ C1477 — Transfer case clutch

GEARS March 2009 39

38-pete309.indd 39 2/11/09 10:41:23 AM

 Chrysler’s New All-wheel Drive System

Figure 3: BW44-40 transfer case “Heart” of the AWD system

over temperature. Indicates the DTCM

has received a signal from the transfer
case temperature sensor indicating the
transfer case fluid is too hot. Check
the transfer case temperature sensor
circuit, wiring and connections. Check
transfer case lube circuit.
C147A — Transfer case tem-
perature sensor high. Indicates the
DTCM has detected an abnormally
high voltage in the transfer case tem-
perature sensor circuit. Check tempera-
ture sensor circuit, wiring and connec-
tions. Check transfer case temperature
sensor. Repair as needed.
C147B — Front axle disconnect
circuit sensor performance. Indicates
the DTCM has detected a performance
problem in the front axle disconnect
sensor circuit. Check front axle discon-
nect sensor circuit, wiring and connec-
tions. Repair as needed.
C147C — Front axle disconnect
power supply circuit low. Indicates the
DTCM has detected low voltage in
the front axle disconnect power cir-
cuit. Check DTCM power and grounds.
Check front axle disconnect power
circuit, wiring and connections. Repair
as needed.
C147D — Front axle disconnect
power supply circuit high. Indicates the
Figure 4: Electronically controlled transfer case DTCM has detected high voltage in

40 GEARS March 2009

38-pete309.indd 40 2/11/09 10:41:35 AM

 the front axle disconnect power cir-
cuit. Check DTCM power and grounds.
Check front axle disconnect power Slauson Transmission Parts…
circuit, wiring and connections. Repair
as needed. Right Part, Right Price, Right Now!
C2100 — Battery voltage low.
Indicates the DTCM has detected low
voltage to the DTCM. Check battery
or system voltage. Check charging sys-
Use d , N ew & Reb u i l t H a r d Par t s , S o f t Par t s ,
tem. Check DTCM power and grounds. E l e c t r i c a l C o mp o n e n t s & F l y w h e e l s
Repair as needed
C2101 — Battery voltage high. O r d e r o n l i n e a t S l auson .c o m
Indicates the DTCM has detected high
voltage to the DTCM. Check battery or O f f e r i n g q u a l i t y p r o d u c t s f r o m t h e s e f i n e ve n d o r s :
system voltage. Check charging sys- 4R A N S T E C s 2 AY B E S T O S s $ Y N A X s 3 O N N A X
tem. Check DTCM power and grounds. 3 PX & I L T R A N s , U B E ' U A R D s 4R A N S G O s " O R G7A R N E R
Repair as needed. 3 U P E R I O R s 2 O S T R A s 4E C K 0A K s ( AYD E N s 4R U # O O L
C2112 — Sensor supply volt-
! U T O C R A F T !4 3 ' s ! L L O M A T I C s ! L T O
age circuit high. Indicates the DTCM
has detected high voltage on the trans-
fer case sensor circuit. Check DTCM Phone Hours: Open 7:00 am to
power and grounds. Check sensor cir- 5:00 pm/ PST
cuit, wiring and connections. Repair as
#ALL  
needed.
C2201 — Internal controller ,OCAL  
failure. Indicates the DTCM has detect- &!8  
ed an internal failure. Check DTCM
power and grounds. If code returns,
replace DTCM.
U0001 — Can C buss. Indicates
a CAN C buss circuit problem. Check
CAN C buss wiring and connections.
Repair as needed.
U0100 — Lost communication Toll Free (800) 428-8489 • Fax (805) 604-2001 • Email [email protected] • Website www.atrabookstore.com
with ECM/PCM. Indicates the DTCM
has lost communication with the ECM/
PCM. Check communication with PRICE BREAK ON OUR
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U0101 — Lost communication

with TCM. Indicates the DTCM has
lost communication with the TCM.
Check communication with other mod-
ules. If communication with all other
modules is possible, check TCM power
and grounds. Check TCM CAN C buss
circuit, wiring and connections. Repair
as needed. Possible TCM failure.
U0121 — Lost communica-
tion with ABS. Indicates the DTCM
has lost communication with the ABS
control module. Check communication
with other modules. If communication Please mention this ad when placing your order. Place your order before 12pm PST and receive same day shipping.
with all other modules is possible, Sale ends 3/31/09

GEARS March 2009 41

38-pete309.indd 41 2/11/09 10:42:09 AM

 with FCM/TIPM. Indicates the DTCM
has lost communication with the FCM/
TIPM. Check communication with
other modules. If communication with
all other modules is possible, check
FCM/TIPM power and grounds. Check
FCM/TIPM CAN C buss circuit, wir-
ing and connection. Repair as needed.
Possible FCM/TIPM failure.
U0212 — Lost communication
with SCM. Indicates the DTCM has
lost communication with the SCM.
Check communication with other mod-
ules. If communication with all other Drive Train control relay connector terminal i.d.
modules is possible, check SCM power
and grounds. Check SCM CAN C buss ABS. Indicates the DTCM has received Refer to the appropriate service
circuit, wiring and connections. Repair data from the ABS control module that manual for your specific vehicle’s diag-
as needed. Possible SCM failure. doesn’t match conditions or is out of nostic routines.
U0401 — Implausible data range. Check data in ABS module. Well, there you have it: a closer
from ECM/PCM. Indicates the DTCM U0429 — Implausible data from look at Chrysler’s new ITM 3e All-
has received data from the ECM/PCM SCM. Indicates the DTCM has received Wheel Drive System. With a basic
that doesn’t match conditions or is out data from the SCM that doesn’t match understanding of how Chrysler’s new
of range. Check data in ECM/PCM. conditions or is out of range. Check ITM 3e All-Wheel Drive System oper-
U0402 — Implausible data from data in SCM. ates and a quick look at the diagnostic
TCM. Indicates the DTCM has received U0431 — Implausible data routines available, you should have no
data from the TCM that doesn’t match from FCM/TIPM. Indicates the DTCM problem keeping those trannys rolling.
conditions or is out of range. Check has received data from the FCM/TIPM
data in TCM. that doesn’t match conditions or is out
U0415 — Implausible data from of range. Check data in FCM/TIPM.

2009 ATRA Technical Seminars

Helping you get your customers back on the road...FAST!
Dates Locations
A Changing Industry
3/21/09 Houston, TX
Today’s business climate is more challenging than ever
before and reliable technical training is a key factor in
3/21/09 St. Louis, MO
remaining up-to-date and profitable. As technology 3/28/09 Boston, MA
changes, you can be sure ATRA will be right there helping
you help your customers. Because...
4/4/09 Minneapolis, MN
Our goal is your success! 4/18/09 Salt Lake City, UT
4/25/09 Fremont, CA
5/2/09 Toronto, ON
The transmissions we’ll
5/9/09 Denver, CO
be covering are:
5/30/09 Des Moines, IA
GM: CHRYSLER:
4T40/45 TCC Surge Updates 68RFE 5/30/09 Dallas, TX
4T65E Sprocket support issues AS68RC 6/13/09 Vancouver, BC
4T80E TCC Buzz noise
4L60/65/70E P0756 issues MERCEDES: 8/1/09 San Antonio, TX
722.6
5L50, 6L50/80/90
LCT 1000 722.9
8/8/09 Los Angeles, CA
Updates--all units 8/22/09 Cincinnati, OH
FORD: TOYOTA: 4X4: 8/29/09 Chicago, IL
AWF-21B U250E Chrysler 10/17/09 New York, NY
6F50N GM
4R70W-4R70/75E
Check ATRA.com for more dates and
Torqshift
locations to come!
Erratic
speedometer Registration Costs:
operation EMI Prepaid, preregistered ATRA members $149
issue Prepaid, preregistered non-ATRA members $189
On-site registration $210

Register Today! Register online and save $10 per person

One free registration with every four paid.

800.428.8489 805.988.6761

ATRA Seminar Registration

2400 Latigo Avenue
Oxnard, CA 93030  www.ATRA.com
www.ATRA.com

GEARS March 2009 43

38-pete309.indd 43 2/12/09 3:51:29 PM

 Chrysler’s New All-wheel Drive System

Figure 5: Drive Train Control Module (DTCM) wiring schematic

Drive Train Control Module (DTCM)

connector terminal i.d.

check ABS control module power and

grounds. Check ABS CAN C buss cir-
cuit wiring and connections. Repair as
needed. Possible ABS module failure.
Front Axle Disconnect connector terminal i.d. U0141 — Lost communication

42 GEARS March 2009

38-pete309.indd 42 2/12/09 3:51:15 PM

 Flu id Matters:
The Wrong ATF Can
Ruin Your Re build by Mark Mustard
TCRA President

Y
ou’ve just completed a rebuild
on a late model ZF. You replaced
all the clutches and seals, and
installed a rebuilt converter. You put the
unit back into the car and fill it to the
correct level. Once you have everything
buttoned up, it’s time for a test drive.
It doesn’t take long to notice the
problem: a chatter when the converter
clutch applies. Everything else seems
fine… sort of. Well, maybe the clutch
applies are a little firm, but not so
severe that the customer will notice.
But there’s no way you can deliver the
car with this TCC chatter. You’re going
to have to pull the transmission back
out and replace the converter… again!
Wait… don’t blame the torque con-
verter or the converter clutch just yet.
They may not be causing the chatter.
But then, if the converter’s okay, why
is the clutch chattering?
How about the fluid? modifier, many transmissions work just ibility problems with the ATF. But if
Once upon a time, automatic trans- fine with Dexron. you run into a converter clutch chatter,
mission fluid came in two different But some transmissions aren’t so suspect the fluid before replacing the
flavors: Type A and Type F. Type F forgiving. In some cases the type of converter a second time. Replace the
went into Fords that used bronze clutch clutch material you used won’t apply fluid with a factory fill and try again.
facings, and everything else took Type smoothly with Dexron, even though it If the chatter goes away, you know that
A. So remembering which one you worked fine in another transmission. this is one unit that just won’t get cozy
needed for which transmission wasn’t In others, no amount of coaxing or with Dexron.
all that difficult. modifiers will overcome the differences Of course, you can improve your
That was over a quarter century between Dexron and the factory fill. ZF rebuild’s durability and shift quality
ago. Today there are hundreds of dif- units are a good example of a transmis- with one of the additive packages from
ferent units on the road, and dozens sion that’s usually a lot happier with the Lubeguard or Life, even when used
of different oils made to address their manufacturer’s brand of ATF. with the factory fill.
individual performance characteristics. So how can you be sure which Just remember, if the converter
Some of those oils cost a bundle: as units will accept Dexron and which clutch chatters, make sure you aren’t
much as $45 a quart! won’t? Start by following the recom- fighting a fluid compatibility problem
Between all the different types of mendations in the application guides before you start replacing the convert-
fluid and their extreme costs, there’s from Lubeguard and Life, available on er… for a second time.
no way any shop can keep a reason- line at the ATRA Tech Center, under the
able selection in stock. So many shops Quick Reference link.
try to save by using Dexron in every These guides provide the informa-
transmission. When used with a friction tion to help you avoid most compat-

44 GEARS March 2009

44-mustard309.indd 44 2/12/09 12:55:12 PM

 Precision matters.
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FROM THE GLOBAL LEADER IN AUTOMATIC
TRANSMISSION SYSTEMS TECHNOLOGY.

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borgwarnerplcd.indd 25 4/11/06 3:26:05 PM

 Taking Advantage of Murphy’s Law:
Answer the Phone All
Day, Every Day by Steve Bodofsky

Like so many other things, cars don’t break down on a schedule. So you can pick up
additional work simply by picking up the phone 24/7.

M
urphy’s Law tells us that
“anything that can go
wrong probably will.” And
time and time again, Murphy has been
proven right. In fact, today there are
dozens of corollaries to Murphy’s Law,
including:
• An open-faced sandwich will
always fall peanut butter-side
down (directly proportional to the
cost of the carpet, and inversely
proportional to the carpet’s age).
• Your kids (or pets) will always
get sick after the doctor’s office the phone at that late hour will dramati- fee to have it added to your shop phone.
has closed (usually Christmas Eve, cally increase your chances of getting Call your phone service provider for
after 6 pm). that job, and dozens of jobs like his that details and to add call forwarding.
leave the customer stranded at all hours Once you have call forwarding on
And most importantly, a car will of the night or weekend. your shop phone, using it is simple.
always break down at the most inop- Sure it’d be nice to get that work, Here’s how Verizon’s call forwarding
portune moment, and during the most but who wants to sit at their shop 24 plan works; most others work in a simi-
inconvenient conditions. Like when hours a day, 7 days a week, waiting for lar manner:
you’re out for the evening and stuck those late night calls? Fortunately you • Pick up your phone receiver and
on a long stretch of road, miles from don’t have to; you can be available to press *72 (on some areas it’s 72#).
home. And of course it’ll be at 9 pm or answer the phone without being there, • When you hear the tone, enter the
later… long after every shop has closed using two simple, 21st century solu- number you want the call forward-
for the day. tions: call forwarding and a cell phone. ed to, including the area code.
But a customer who’s stuck in • That phone will ring. Once you
that situation won’t let a little thing Call Forwarding answer it, call forwarding is
like logic get in the way. He’s going Call forwarding is a service from active.
to try calling your shop anyway, in the your phone company that’s available
unlikely prospect of finding someone nearly everywhere across the country. Now, when someone calls your
there to help him out of his jam. If you have a bundled phone package, shop phone, the call will automati-
Wouldn’t it be great if you were you may already have call forwarding cally forward to the phone number
there to answer his call, and help him included in your service plan; otherwise you entered; in this case, a dedicated
in his time of need? Simply answering you may have to pay a small monthly cell phone. It’ll continue to forward

46 GEARS March 2009

48callfwd.indd 46 2/11/09 1:51:22 PM

 all calls until you deactivate call for- efit. There may be additional fees for
warding when you get into the shop taking forwarded calls on a cell phone;
the next morning. To the customer it’ll this can include long distance fees
be completely transparent; as far as he or additional minutes. Check ahead
knows, you’re at the shop answering
the phone.
To deactivate call forwarding the
next morning, just hit *73 (73# in some
of time to make sure what they’ll be
charging you, and adjust your service
plan or provider to keep your costs as
low as possible.
24/7
areas). Once you hear two short tones, Remember that this is just an exten-
call forwarding is deactivated. The calls sion of your shop phone. You should
will come to the shop phone again. answer it the same way you do the shop
phone, in the same, professional man-
Dedicated Cell Phone ner. Sure, some of those calls will wake
Next you’ll want a dedicated cell you out of a sound sleep, or interrupt
phone for taking shop calls. Why a your dinner. Try not to sound that way.
dedicated phone instead of simply Do you use the ATRA Phone
using your regular cell phone or home Procedure in your shop? You should,
phone? For one thing, since it’s a dedi- and you should have a Phone Procedure
cated phone, you’ll know to answer pad available at your home, as should
whenever your shop phone is set for everyone who takes a turn at answer-
call forwarding. Such as when it rings ing the night and weekend calls. That
at 2 am, or early on Sunday morning. way you won’t have to think about how
And it’s a phone you’ll want to leave you’re answering the phone, no mat-
on all night. ter what time of day it is. Contact the
Second, when the dedicated phone ATRA BookStore to order a Phone Pad
rings, it’s just like your shop phone; starter kit or additional pads.
you’ll answer it the same way: “Thank
you for calling Central Transmissions. 24/7 Towing Service ing morning. Make it a point to call
My name is Jim. How can I help If someone calls you at 2 in the the customer first thing when you get
you?” morning, chances are they’re stuck in, just to let him know you have his
Sure, many of today’s cell phones somewhere. If they were home, they’d car, and to clarify any details about
also offer unique rings, depending on probably wait until later to call. So the problem. And let him know when
who’s calling. But a separate phone you’ll have to send someone to get you’ll be bringing the car in to check
eliminates any question about who it is, them… right now. it out. That keeps the customer in the
or whether to answer or not. If it rings, You’ll need to have a towing ser- loop, and helps build his confidence in
it’s a shop call, and you’ll answer it that vice available, offering dependable your shop.
way. Period. towing, 24 hours a day, 7 days a week.
Finally, using a dedicated phone When a customer calls, you’ll take Market It
allows you to pass the phone around, the information about where the car is Once you’ve committed to the idea
and give everyone a chance to handle and how to contact the customer. Then of answering the phone at all hours of
the late night calls. Let’s face it, some you’ll call the towing company and the day and night, don’t forget to let
of those calls may come in at really send them right out to pick up the car. the world know. Add it to your Yellow
inconvenient hours — that’s the whole Never simply forward the call to Pages ad: Available 24/7, 365 Days a
idea of using call forwarding on your the towing company, or ask the cus- Year!
shop phone. So you aren’t going to be tomer to call them directly; you want Remember, the customer who’s
able to handle the calls yourself all the to remain in control of the customer looking for a shop to call at 2 am
time. You’ll want to share the respon- and his car. doesn’t have a lot of confidence that
sibility with others, so everyone has a If you have a gated parking lot, he’s actually going to reach anyone.
chance to get a good night’s sleep or give the tow truck driver a key to the That simple statement on your ad will
go out for the evening once in awhile. lot, so he can bring the car right in and draw his eye, and you can be sure he’ll
A dedicated phone makes it easier to lock it in your secure parking area. be calling your shop. All that’s left for
share the job with other members of Some people will call the towing you is to answer the phone.
the shop. company directly when they have a Anything that can go wrong prob-
The services you require for this problem. Work out a deal with them ably will… especially when it comes to
type of phone may be vastly different to bring potential customers directly your car. But you can turn Murphy into
from those on your regular cell phone. to your shop, and you’ll pick up even your greatest ally by taking customer
You probably won’t need texting or more new customers. calls 24/7, 365 days a year.
internet access; but unlimited nights Don’t forget to get a contact num-
and weekends will probably be a ben- ber to reach the customer the follow-

GEARS March 2009 47

48callfwd.indd 47 2/11/09 1:52:25 PM

 by Steve Bodofsky
SHOP PROFILE

Santa Rosa
Transmissions
Sam Burrage; Owner
A
ccording to many shops
from all across the country,
car counts and profits have
been abysmal for years. But through
it all, Sam Burrage’s shop, Santa Rosa
Transmissions, has managed to remain
busy. What’s his secret? Where is he
finding so much work when other shops
are barely holding on?
“Probably the most important thing
is having a good reputation,” explains
Sam. “I don’t care how much you
advertise; it won’t overcome a bad
reputation. We have a great reputation
here in town for being straightforward
and honest and doing good work.”
Over the years Sam has worked on
developing his reputation for honesty
and providing quality work. “Always
treat people as if your roles were
reversed, and you were the one on the San Francisco, the shop where Sam got equipment… it helps me hire better
other side of the counter,” he says. his feet wet in the transmission repair people because I can more easily iden-
“How would you want to be treated? business. tify a talented technician.
Most people aren’t looking for some- After graduating high school, Sam “But I owe my success today from
thing for free; they want an honest job went to a local college where he stud- learning to think like an entrepreneur
at an honest price.” ied transmission technology. “It was and not like a mechanic,” concludes
It’s that attitude that’s helped build a valuable experience because that’s Sam. And a big part of that thinking
the reputation of this ATRA-Member where I learned the theory to support involves the work he does in the com-
repair shop as the shop for auto repair the rebuilding skills I learned in my munity of Santa Rosa, building his
service in the Santa Rosa area. father’s shop,” says Sam. reputation… and his business… each
But while his introduction to the and every day.
Three Generations of industry was from the technical side,
Transmission Repair today Sam no longer considers himself Getting the Word Out
That reputation didn’t happen a technician. “I’m a businessman/entre- So how do potential customers find
overnight. It’s a legacy that spans three preneur with a strong technical back- Santa Rosa Transmissions? What type
generations, beginning with Sam’s ground,” he says. “I have a skilled staff of advertising brings in those custom-
grandfather, William, who started fix- of diagnosticians and rebuilders who ers? “A large part of our work comes in
ing automatic transmissions back when handle that end of the business. directly from referrals, or is backed up
they first began rolling off the Detroit “My technical background is a by referrals,” says Sam.
assembly lines. valuable resource, because it helps me “Customers also come in because
William taught the business to understand what my technicians are of our relationship with associations
Sam’s father, Bill, and uncle, Ed. They dealing with on a daily basis… it helps they’ve learned to trust, such as ATRA
went on to open B&E Transmissions in me recognize when they need new and AAA. People see those credentials

48 GEARS March 2009

48shopProf.indd 48 2/12/09 2:44:33 PM

 Never underestimate
the value of the
first impression:
“Our shop is clean
and neat, and there
aren’t any junk cars
in the parking lot.
as an indication of honesty and profes-
sionalism.”
Never underestimate the value of
the first impression: “Our shop is clean
and neat, and there aren’t any junk cars
in the parking lot. There are no dirty
parts or oil stains on the floor as they
walk into the office. We have a clean,
friendly waiting area that creates a myselfSam
as aBurrage,
businessDennis
owner.Burkett
I don’t(Sams
do Uncle),
the store
RickorBurrage
to school.
(Sams“People
Uncle) want
great first impression for new custom- and Thomas Brown at ATRA's Powertrain Expo, Las Vegas
ers. Those first impressions are lasting
impressions… they set the tone for the
rest of your transaction.”

Community First
While Sam recognizes the need for
advertising, he’s quick to point out that
the most valuable resource for bring-
ing customers in is through community
involvement.
For example, Sam is currently a
board member for the local Automotive
Service Council (ASC), where he regu-
larly meets with other automotive ser- The Santa Rosa Transmissions Team
vice business owners. And he’s a mem- Dennis, Tom, Sam, Tawnia, Rick and Aaron
ber of the local Chamber of Commerce;
a membership that allows him to meet
with other local business owners and this as a marketing tool; I do it because to do business with members of their
community members. it’s important to me. community; it’s about finding common
He’s also been a member of dif- “But when you’re involved with ground,” says Sam.
ferent “leads” groups, where members your community, people talk to you.
meet to share business leads and ideas They’ll ask, ‘Hey Sam, what do you do Advertising His Shop
with one another. And he’s sponsored for a living?’ and that gets your name While Sam acknowledges the
a few Little League teams over the out there. You become their ‘friend in importance of word-of-mouth referrals
years. the business,’ and it eventually turns and community involvement, he also
Another way Sam works to give into new leads… and new customers. recognizes the importance of main-
back to his community is by volunteer- The additional business is a side-effect taining an advertising presence. He
ing with a local hospice group, visit- of being an active member in the com- still advertises in the Yellow Pages,
ing and helping terminally ill patients. munity.” and has a beautiful web site at www.
Many are living out their last days Sam also lives right near his shop, SantaRosaTrans.com.
alone. in Rohnert Park — one town over from This year, based on some things
Sam doesn’t volunteer for any per- Santa Rosa. So it’s a common occur- Thom Tschetter mentioned at a recent
sonal benefit: “I didn’t go into (hospice rence for him to run into his customers Expo, Sam reduced his Yellow Pages
care) as a tool to improve my business; while at the supermarket, a restau- ad presence. “I’ve always run big ads
I don’t walk in wearing a Santa Rosa rant, or taking his 10-year-old daughter in the phone book, but this year I’ve
Transmissions shirt or even identify Alyson or 5-year-old son Gavin to decided to switch to a single listing. I’m

GEARS March 2009 49

48shopProf.indd 49 2/12/09 2:45:02 PM

 Santa Rosa Transmissions

convinced that people go to the phone

book to find someone they already
know, not to get sold on a new shop.”
And no wonder: Those big ads in
the Yellow Pages cost thousands of dol-
lars every month; you have to fix a lot
of cars just to pay for that ad.
Instead, Sam has put more effort
into his web site. “Too many people get
their new phone book and drop it right
into the recycling bin. The business
world is changing, and more people
are turning to the internet when they’re
trying to find a business.”
Santa Rosa’s web site offers poten-
tial customers a terrific view of their
shop. It provides a brief overview of
the company philosophy, introduces
the staff, and explains the services
they offer. There’s even an “Ask the
Santa Rosa Transmissions
Mechanic” page, where customers can
mail their questions to be answered by
a technician.

Surrounding Himself
with Talented People
There’s little doubt that a key ele-
ment in any successful business is to
surround yourself with talented people.
Sam is quick to acknowledge the con-
tribution his employees make to Santa
Rosa’s success.
Two of his employees are also
family members: His uncles, Dennis
Burkett and Rick Burrage, began work-
ing with Sam back when he first started
out in his father’s shop. “These guys
were my first teachers in the transmis-
sion business,” Sam says proudly. Both
Dennis and Rick hold ASE and ATRA
certifications.
Shop Area Tom Brown and Aaron Nelson
round out the Santa Rosa technical
crew. Both are experienced technicians
and both carry ASE certifications.
Tawnia Pometta is the office man-
ager, and the newest member of the
Santa Rosa staff. It’s her friendly voice
that greets people who call for service
or to check on their cars.

More Than Just

Transmissions
Like many other transmission shop
owners, Sam believes that the best way
to remain profitable in today’s economy
is to expand your services. These days
he no longer even considers Santa Rosa
Thomas Brown, Technician to be just a transmission shop: “We’re

50 GEARS March 2009

48shopProf.indd 50 2/12/09 2:45:26 PM

 an auto repair shop that specializes in
transmission repair,” he explains.
But making that transition wasn’t
simply a matter of adding a few words
to the sign out front. Sam is a big
believer in training, and when he decid-
ed to expand the shop’s services, he
made sure the shop was ready for it.
“I take my employees to Expo
every year, and send them to the ATRA
seminars when they come to town. And
a couple of my employees are taking
additional courses at the local commu-
nity college.”
When will his staff have enough
training? According to Sam, training
isn’t a goal; it’s an ongoing journey…
one that will continue as long as they
keep making new cars. “The cars keep
changing, and the technology changes
Sam and his father Bill Burrage
with it. We need to keep up with those
changes if we’re going to keep fixing
them.”
While Santa Rosa is predominately
a transmission repair shop, Sam isn’t
ashamed to admit that he uses remans
when necessary. “Last week I had four
transmission jobs come in. We were
able to rebuild two ourselves, but the
only way I could be sure to get the rest
out was to use remans for the other
two.
“I’m okay with that; it’s about serv-
ing my customers. By using remans,
I was able to take care of all of my
customers in a timely manner. That’s
important to them, and that makes it
important to me.”
Sam also uses remans when a cus-
tomer comes in from out of town. “It
just makes good sense. They get a good
warranty that’s covered anywhere in Aaron Nelson, Technician
the country. They’re happy and that’s
good for all of us.”
What would Sam consider to be
the most valuable secret to his success?
“The trick is getting past the walls of
your business to become the guy people
know from the community. Suddenly
they can associate a person with the
business name, instead of just a brick-
and-mortar building with a sign out
front. People want to do business with
people, not just a name.”

Building Area

GEARS March 2009 51

48shopProf.indd 51 2/12/09 2:45:44 PM

 www.atra.com

Arguments against the Accelerated

Retirement of Inefficient Vehicles Act
New legislation is being introduced that's
designed to get older, less fuel efficient cars
and trucks off the road; it's called the
"Accelerated Retirement of Inefficient
Vehicles Act." This legislation is being intro-
duced by Senator Diane Feinstein (D-CA)
and Representative Henry Waxman (D-CA).
The idea is to pay people to scrap their older
cars and use that money to help purchase
newer cars. This could have a dramatic affect
on the aftermarket repair industry. Several
organizations, including ATRA, sent a joit
letter to Speaker Nancy Pelosi, raising con-
cerns on behalf of the aftermarket repair
industry.
We urge you to contact your senators and
representative and voice your concerns. If
you'd like more information on this go to:
http://www.sema.org/Main/ArticleDetail.
aspx?contentID=61095

continued on page 53

Page one of the letter sent to Washington, DC

How important is it that we love our jobs?

Work/life balance expert Jim Bird doesn’t necessarily mean you’re liv- enjoy.
( www.worklifebalance.com) says we ing your life less well than the indi- • Cook dinners that will make your
hear all the time how important it is vidual who is passionate about work. friends swoon.
to have jobs we love. Yet most peo- Your passion may surface in regard • Go to your favorite sporting events.
ple he knows don’t love their work. to other areas of your life. Bird offers • Let the people you’re closest to
They either accept it or tolerate it. these suggestions for generating know how much you adore them.
And that’s okay, Bird says. He points more ardor for living:
out that while it’s not necessary to be The key is to set aside time for
passionate about your job, you • Write the essay or book that’s been doing whatever it is you love to do.
should be passionate about how well in the back of your mind. The first step is deciding you’re
you do the job. Why? Because that’s • Take a class in a subject that you going to do it. The important second
what you do for yourself. enjoy. step, Bird says, is to go for it.
Lacking passion for your job • Teach a class in the subject that you à

52 GEARS March 2009

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 ATRA News

Inefficient Vehicles Act continued

Page two of the letter sent
to Washington, DC

Page three of the

letter sent to
Washington, DC

Download a PDF
version of this letter
online at www.atra.
com/gov

GEARS March 2009 53

52-atraKEL309.indd 53 2/12/09 9:58:12 AM

 www.atra.com

More IRS rulings for

tool reimbursement
ATRA is aware of increasing pressure
from the IRS for back taxes for shops that
have participated in tool reimbursement
plans. The IRS does not claim that the
concept is illegal, but… they have more
clearly defined what is acceptable for a
plan to be considered an "Accountable
Plan". Last year the IRS issued a position
paper detailing the three criteria needed
for an accountable plan, and they've
included several scenarios of existing tool
plans that do not meet the criteria as sam-
ples. You can find the position paper at:
http://www.irs.gov/businesses/
article/0,,id=97388,00.html
If you are participating in a tool plan or
have participated in a tool plan in the past
we advise you to take a copy of the IRS www.irs.gov/businesses/article/0,,id=97388,00.html
position paper to your tax accountant for
review. à

Without Customers...Where are you?

ATRA helps you...

FIND CUSTOMERS FIX THEIR VEHICLES

Nationwide Warranty Program Technical Seminars

&
Recognized Certification Technical HotLine
Pre-designed Advertisements ATRA’s Online Tech Center
Newspaper Ads Testing & Certification
Radio Spots Books & Monthly Bulletins
Television Spots GEARS Magazine
Commercial Footage ATRA’s Powertrain Expo
Professional Website Design Technical Training

Apply for ATRA Membership Today

(866) GO-4-ATRA • (866) 464-2872

www.atra.com/join

54 GEARS March 2009

52-atraKEL309.indd 54 2/12/09 9:58:28 AM

 ATRA News

Congratulations to Wayne Russell of Manchester, New Hampshire

Wayne's business received the
first CSI report for 2009 from
ATRA. The report shows the
responses from his customers
that submitted the CSI survey
cards in the 4th quarter of 2008.
These cards come directly to
ATRA for analysis and the
report helps ATRA members get
a better understanding of their
customers' satisfaction with their
work. Russell Automotive Inc
scored a 98% with this batch of
cards and received a press
release announcing this achieve-
ment to his local community. à

Consumer Index Report

Congratulations
Wayne!

ATRA Press R
elease for Wayn
e Russell

GEARS March 2009 55

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 www.atra.com

————————Internet Hot Spot————————

www.facebook.com waiting
There are advertising opportunities ever before. Change your status
for you to take advantage of updates to reflect your business, blog
them on many of the Social Media your thoughts and rebuilding experi-
If you don’t have a Facebook
sites. Other sites to check out are: ences for the day, or post a video of
account, you could be missing out on
www.myspace.com that classic car you rebuilt last month.
advertising opportunities.
www.blogger.com All these extra sites, promote current
Not only is Facebook used to stay
www.youtube.com topics, updated regularly about your
in touch with family and friends, this
business. You can’t go wrong with
Social Media Optimization opportuni-
With these social websites work- more advertising. à
ty allows you to advertise as well as
ing for you, networking is easier than
network with others in similar groups.

New Golden Rule Warranty Logo Workplace Safety

All members are now permit- now be able to use this logo in Although some workplace
ted to use the ATRA Member advertisements and for display distractions and interruptions are
Logo. The original use of the on shop websites. In addition, unavoidable, many can be con-
logo was intended to be dis- within the shop finder search trolled or prevented. No matter
played by Rebuilder members results on the www.atra.com what the distraction, your first
only as they were participants in website, Rebuilder members concern should be to keep your
the Golden Rule Warranty will now have the Golden Rule mind and your focus on safety –
Program. The Warranty your safety and that of others.
problem was it logo dis- Be aware of any distractions you
wasn’t clearly played next may be causing and take respon-
written on the to their shop sibility for not interrupting oth-
logo that that information ers. Let your supervisor know
was the pur- as well. about repeated and/or unsafe
pose. ATRA is distractions.
With that in preparing to Work interrup-
mind the need have the tions are a distrac-
for a new logo new logo tion that can result
especially for available as in work errors or
Rebuilder a window accidents. Before
Members of the sticker for addressing or
association was purchase in responding to
apparent. The new logo is com- the BookStore. another person,
pleted and available for use by For use and guideline on the shut down or dis-
all Rebuilder Members of the new Golden Rule Warranty engage any work
ATRA. Logo, please visit the tool. à
All Rebuilder Members will ATRA website downloads area.

56 GEARS March 2009

52-atraKEL309.indd 56 2/12/09 9:59:15 AM

 GEARS does not endorse new products but makes this new information available
POWERTRAIN INDUSTRY NEWS 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.

Sun Capital Closes Transtar Industries TransTec Introduces New

Crawfordsville Plant Ranked World-Class Ford 6F50, GM 6T70/75 Kit
Raybestos Powertrain in Customer Service In 2002 Ford and General Motors
Unaffected Transtar Industries, Inc. recently joined forces to design a new, compact,
completed a survey with a random sam- six-speed, front-wheel drive automatic
Sun Capital Partners announced pling of its customers. MarketVision transmission. Each company gave the
that Friction Holdings LLC (“Friction Research, an independent research firm unit its own designation and manufac-
Holdings”) intends to cease all opera- with over 25 years of research experi- tures it in its own plant.
tions on or about February 28, 2009. ence, conducted the survey. In support Ford has one designation, 6F50,
Friction Holdings has operations at of Transtar’s customer-centric focus, while GM has two designations: the
Crawfordsville, IN and Greenwood, this survey takes a third-party objective 6T70 for standard applications, and
MS. look at Transtar’s customer satisfac- 6T75 for higher torque applications.
During 2008, the automotive and tion. Corteco is pleased to announce the
light duty truck industry has suffered “Keeping in touch with our cus- availability of TransTec® overhaul kits
historic slumps in sales, which left Sun tomers is critical to our success,” states 2518, 2519, 2520 and 2521. Kits 2518
Capital with no choice but to reorganize Tom DeMille, Vice President of Sales and 2519 will cover the 2007-up Ford
its plant operations and cease opera- and Branch Operations. “We need to 6F50; kits 2520 and 2521 will cover
tions at Friction Holdings. understand how our customers’ busi- 2007-up GM 6T70 and 6T75 applica-
“Over the last year, we’ve expe- nesses and needs are changing so we can tions.
rienced significant improvements in more effectively meet these needs.” Kit Applications
operating performance that all Friction Overall, 97% of customers surveyed Application Description
TransTec®
Kit Number
Holdings employees should be proud reported being satisfied or very satis- Ford 6F50 Without Bonded Pistons 2518
of. Unfortunately, these improvements fied with the service they receive from Ford 6F50 With Bonded Pistons 2519
haven’t been adequate to offset the loss Transtar. According to MarketVision, GM 6T70/75 Without Bonded Pistons 2520
of a significant portion of our customer this rating indicates that Transtar pro- GM 6T70/75 With Bonded Pistons 2521
base,” said Daniel A. Gaston, President vides World-Class Customer Service to
and CEO, Friction Holdings. its customers. Application Description
TransTec®
Kit Number
Raybestos Powertrain plant in “We truly appreciate our cus- 6F50, 6T70/75 Axle Seal-Right B37107
Sullivan, Indiana will continue opera- tomers,” says Neil Sethi, Group Vice 6F50, 6T70/75 Axle Seal-Left B37108
tions and look to expand its manufac- President, Transtar Distribution Group. 6F50, 6T70/75 Converter (Front) Seal B37109
turing capacity, to provide a seamless “We desire to be our customers’ partner, 6F50, 6T70/75 Valve Body Cover Gasket B33373
and ongoing supply of OE and OE not just their vendor. This survey shows 6T70/75 Valve Body Gasket Kit 4826
6F50 Valve Body Gasket Kit 4830
equivalent parts for the aftermarket. that we are successful in this endeavor,
“We are a US manufacturer that even during these difficult economic
will remain a US manufacturer for a times.”
long time to come. Our distributors can “These scores reflect the hard work
expect the same uninterrupted supply of and dedication of our sales team, who
Raybestos product that they’ve come to put our customers first,” Sethi contin-
rely on with no change in service level,” ues. “We’re proud of the exceptional
said John Butz, President and CEO of service levels of our staff, and will use
Raybestos Powertrain. this information to build on the work
Raybestos Powertrain will contin- we do well, as well as improve in the
ue its strategic alliances with MEANS areas where customers say we can do a
Industries, Filtertek, NTZ and others. better job.”
Raybestos Powertrain devel- Transtar Industries, Inc. is a world- NTZ Micro Filtration
ops, manufactures and supplies OE wide manufacturer and distributor of
and aftermarket component parts for quality transmission parts and services.
Relocates to
use in an oil-immersed (wet) envi- For more information, visit the Transtar Expanded Facility
ronment. To learn more, visit the web site at www.transtar1.com. NTZ Micro Filtration has announced
Raybestos Powertrain web site at its relocation to Wixom, Michigan to
www.raybestospowertrain.com. expand its current operations. The new
facility allows for onsite testing, product
development, and logistical distribution

GEARS March 2009 57

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 POWER INDUSTRY NEWS
to provide a wider range of services to 3-2 coastdown shift, and 2-3 flare with www.northcoastbearings.com.
its North American customer base. the B-4 Release Valve Kit, Sonnax P/N Along with NCB products, the new
NTZ develops and manufactures 59947-26K. This upgrade kit includes site features DT Components®, a premi-
micro filtration technologies for trans- a hard-coat anodized valve and an O- um line of transmission, differential and
mission, engine, and hydraulic sys- ringed aluminum end plug to prevent transfer case rebuild kits and compo-
tems in the automotive OEM and after- wear. A replacement spring is included nents for truck applications distributed
market. Applications include the Ford to ensure proper calibration. by North Coast through its strategic
TorqShift® transmission micro filter, Installing this repair kit requires alliance with The Timken Company.
advanced transmission filtration devel- the F-59947-TL26 tool kit and the VB- “This is the first time that the NCB
opment for dual clutch (DCT), continu- FIX holding fixture. and DT Components® product lines
ously variable transmissions (CVT), For more information on this or have been consolidated under a single
industrial and heavy-duty engine filtra- any of Sonnax’s line of repair kits, stop web site, making it easier for distribu-
tion. by the Sonnax web site at www.sonnax. tors to meet virtually all of their drive-
Headquartered in Rotterdam, The com. train needs from a single distribution
Netherlands, NTZ’s North American point,” said North Coast Bearings Vice
location in Wixom provides fluid con- VBX Moves to Larger President of Sales Ken Lark. “What’s
tamination solutions to support the more, the site includes links to our
NAFTA region. The company also has
Facility parent company, Bearing
a manufacturing facility in Oscoda, Technologies, with access
Michigan. to even more products.”
NTZ’s patented micro filter sys- Detailed product
tems provide superior fluid cleanliness information and applica-
compared to that realized by standard tion data is available in
filters. Ultra-fine filtration has sever- downloadable brochures,
al positive effects on fluid systems flyers and catalogs in pdf
as a result of reduced contamination, format from the “litera-
including reduced failures and warranty VBX-ValveBody Xpress is proud ture” section on the site. Included is
claims, consistent performance levels. to announce that they’ve relocated to a the latest DT Components® product
and improved durability. new, larger standalone facility. catalog, a 350-plus page guide cover-
NTZ’s new address is 28221 Beck According to Tim LaCerra, pres- ing virtually every popular vehicle on
Road, Bldg A-1, Wixom, Michigan ident, “The move was necessary to the road.
48393. Its new phone number is 248- serve our rapidly growing customer North Coast Bearings is a sub-
449-8700, fax 248-449-8706. For more base and increasing global demand for sidiary of Bearing Technologies LLC,
information, visit their web site at www. our Guaranteed Remanufactured Valve one of the world’s leading manufactur-
ntzfilter.com. Body Product Line.” ers and private labelers of wheel hub
VBX is now located at 150 Mid- assemblies and clutch release, racing,
Sonnax Introduces New Atlantic Parkway in Paulsboro, New repair and specialty industrial bearings.
Jersey in a state-of-the-art, 32,000 For more information about
AW55-50SN, AF23/33 Kits square-foot facility. North Coast Bearings’ new web site,
Tim would like to sincerely thank please contact John Gross at Bearing
all VBX Distributors, suppliers, indus- Technologies LLC 440-930-7602,
try supporters and his staff for not only email [email protected] or visit www.
making this move possible, but for also northcoastbearings.com.
making a smooth transition from their
old location.
For further information on the new
VBX facility, please call 1-866-2GET-
VBX (1-866-243-8829) www.valve-
bodyxpress.com.

North Coast Bearings

Sonnax is proud to announce the
latest addition to its growing family of
Launches New Web Site
solutions for the AW55-50SN, AF23/33 Distributors can now select, order
transmissions. These units are found and sell the entire line of differential
in selected 2001-up GM, Saturn, Saab, and transmission rebuild kits, bear-
Volvo, Renault, Opel, and Nissan appli- ings and related drivetrain components
cations. from North Coast Bearings LLC (NCB)
Eliminate the 3-2 neutral, harsh — online, anytime at the all-new

58 GEARS March 2009

57-pins309.indd 58 2/12/09 10:28:26 AM

 SuperFlow Introduces
New Premier Transmission
Tester
SuperShifter, a revolutionary tes-
ter/controller that combines years of
transmission testing experience and
state-of-the art electronics into an easy-
to-operate, handheld diagnostic tool for
today’s modern transmissions, is now
available from SuperFlow Technologies who build and balance their own drive- and Accumulator Buddy™ kits. These
Group. shafts, manage their own quality, sched- specially designed wire brush kits are
ule their own delivery and get paid! impregnated with a super fine abrasive
Meet the SuperFlow Axiline to remove small burrs and polish the
SHAFTMASTER. This proven profit inside of valve and accumulator bores
center is easy to operate, requires mini- easily.
mal investment, and produces “factory” The Bench Buddy™ and
welds every time for unmatched perfor- Accumulator Buddy™ kits:
mance, because it’s the first and only • Improve the surface finish of a
The SuperFlow machine that press welds, straightens, bore by up to 50%
SuperShifter is designed for and balances all on one device… and • Restore smooth valve opera-
in-vehicle use and is a proven time- it can be equipped with everything tion in seconds
and money-saving tool for automotive you need to do the job right, including • Service bores from ¼” to 2”
professionals, enabling them to shift specialized tooling to handle anything …and all with virtually no enlarge-
automatic transmissions in the same from PTO-powered tractors to high- ment of the bore diameter.
manner as the vehicle computer. performance off-road vehicles.
The SuperShifter automatically Also available: the Axiline
displays pressure and PRNDL switch Combination Lathe. Two lathes in one
status, temperature and speed sensor — Cut Off and Long Bed configura-
information. It displays solenoid names tions — provide fast, safe removal of
and impedances to help operators deter- old welds, with tailstock and steady rest
mine whether or not test results are machining capability. Variable speed
within spec. It eliminates the need for spindling range is 0-400 rpm.
an ohmmeter or pages of reference The Axiline Press Welder — a
tables and data sheets. Plus, it works great starter machine — lets you start
with dyno, valve body or solenoid test- now and balance later. It’s ideal for
ing equipment. shops that already have build and bal-
SuperFlow Technologies Group is ance stations, but want to add assembly
a worldwide leader in the design and and welding to keep up with demand.
manufacture of Hicklin transmission SuperFlow Technologies Group is
dynamometers, Axiline transmission a worldwide leader in the design and
dynamometers and driveshaft service manufacture of Hicklin transmission
equipment, TCRS torque converter dynamometers, Axiline transmission
rebuilding systems, and SuperFlow dynamometers and driveshaft service With the Bench Buddy™ and
high performance flowbenches, engine equipment, TCRS torque converter Accumulator Buddy™ kits, you can
dynamometers, chassis dynamometers rebuilding systems, and SuperFlow reuse valve bodies and accumulator
and transmission diagnostic equipment. high performance flowbenches, engine bores that may have been question-
For more information or technical con- dynamometers, chassis dynamometers able in the past. No transmission bench
sultation, call 888.442.5546 or visit and transmission diagnostic equipment. should be without these exciting new
them on line at www.superflow.com. For more information or a technical tools from Superior.
consultation, call 888.442.5546, or log And now, Superior has introduced
SuperFlow Introduces on to www.superflow.com. a new 4F27E kit that includes new 1-2
and neutral/drive accumulator pistons
Program for Shops to and sealing rings, and comes with an
Begin Driveline Repair Superior Introduces
Accumulator Buddy brush to smooth
There are two types of driveline
New Bench Buddy™ and out case bores.
repair operations: Those who patiently Accumulator Buddy™ Kits For more information about the
outsource and wait for the repair work Superior Transmission Parts has Bench Buddy™ and Accumulator
or replacements and pay… and those just introduced its new Bench Buddy™ Buddy™ kits, call toll free, 1-800-451-

GEARS March 2009 59

57-pins309.indd 59 2/12/09 10:28:51 AM

 POWER INDUSTRY NEWS
3115, or visit the Superior web site at In his new position, Oakes will be Dye-Lite All-In-One dye is safe
www.superiortransmission.com. responsible for leading the company’s and easy to use. Just one bottle of dye
manufacturing and distribution operation per application is all you need! The dye
Superior Introduces New in Laurinburg, North Carolina. He is a is circulated through the vehicle’s fluid
25-year veteran of the automotive tier 1 system, and will escape with the host
Shift Correction Package and 2 supplier industry specializing in fluid through the tiniest leak. When the
for 4R70E/W, 4R75E/W and actuator, sensor, switch and electronic system is scanned with a high-inten-
AOD-E products. sity Tracerline® UV lamp, the dye will
Prior to joining ACC, Oakes was glow, spotlighting the exact location of
with Stoneridge, Inc where he served every leak. All-In-One is available in
in various posts. standard and concentrated formulas.
”We are pleased to have Mark join For more information about TP-
the ACC team. His strength as a leader 3405CS Dye-Lite® All-In-One™ dye,
of lean manufacturing and six-sigma call toll-free 1-800-641-1133. Outside
disciplines, as well as demonstrated the United States and Canada, call
success in managing manufacturing 516-333-1254, or visit their web site at
transfer projects, will serve our www.tracerline.com.
strategic growth initiatives very well,”
said Thomas P. Petrillo, President and
CEO, ACC.
Oakes received his Bachelor
of Science degree in Mechanical
Engineering from Ohio State University.
Superior Transmission Parts is He currently resides in Southern Pines,
proud to announce it has updated item North Carolina.
KAOD-E to fit all 4R70E/W, 4R75E/W Aftermarket Controls Corporation
and AOD-E transmissions, from 1992 (ACC) is parent company to Rostra
through 2007. This kit will improve Precision Controls, Inc., USA Switch
overall transmission performance while and OEM Components, suppliers to
helping eliminate these common prob- the original equipment and aftermar-
lems: ket automotive industries. For more
• 2nd roller clutch failure information, call 248.960.8500 or visit
• Soft or sloppy 3-4 shifts www.usaswitch.com.
• Slip-bang on takeoff
• Inadequate lube oil Full Spectrum All-In-One™
• 3-4 band failure
• 3rd clutch failure
Dye Pinpoints All Leaks
• Falls out of 4th gear when hot in Oil-Based Fluid Systems
• Converter shudder Tracer Products has developed a
• Soft or sloppy 1-2 shift state-of-the-art fluorescent dye — TP-
• Intermediate loss of 2-3 shift 3405CS Dye-Lite® All-In-One™ dye
We’ve also added a steel, no-stick — which greatly improves leak detec-
solenoid regulator valve. All Superior tion in all oil and oil-based fluid sys-
products work as promised, so be like tems, including gasoline and diesel
thousands of others that have made the engine oil, gasoline, diesel fuel, auto-
shift to Superior Transmission Parts. matic transmission fluid, power steer-
For more information, visit ing fluid, as well as hydraulic and
Superior’s web site at www.superior- lubrication fluids. This dye has proven
transmission.com. to be 100% effective with all UV and
blue light lamps.
Aftermarket Controls Corp TP-3405CS Dye-Lite All-In-One
dye assures optimum leak detection
Names A. Mark Oakes because it actually contains two fluo-
VP of Operations rescent dyes: One fluoresces best under
Aftermarket Controls Corporation UV and the other under blue light.
(ACC), manufacturer of OEM and Whatever type of inspection lamp is
aftermarket automotive parts and used, All-In-One dye will glow bril-
accessories, has appointed A. Mark liantly and spotlight every leak — even
Oakes as Vice President of Operations. a pinhole — in a system.

60 GEARS March 2009

57-pins309.indd 60 2/12/09 10:30:59 AM

 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed
elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.

SHOPPER CLASSIFIED ADS For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

ERICA O RT E D ERIKSSON INDUSTRIES

AMAutomatic N IMP Division of Wentworth Engineering
Standard
Transmission
1946 - 2007
Transmission
1960-2007
1-800-388-4418
800-835-1007
Authorized Parts Distributor

•Remanufactured Units * DYNO TESTED*

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Helping rebuilders get the 1-800-388-4418
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Next day delivery to
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on orders called in by 4pm. 146B Elm St., Old Saybrook, CT 06475

**COMPUTERS**
Transmission Control Module
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GM - Ford - Chrysler - Dodge 800-725-6499
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E Call and
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GEARS March 2009 61

61shoppers309.indd 61 2/12/09 3:07:13 PM

 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed
elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.

SHOPPER CLASSIFIED ADS For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

GEARS
FOR THE TRANSMISSION REBUILDING INDUSTRY

BMW Mercedes-Benz Audi Driveline Specialists

Remanufactured to
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Perfection YOUR AD! and
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1UALITY'EARSUPPLIES
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62 GEARS March 2009

61shoppers109.indd 62 2/12/09 11:30:42 AM

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GEARS March 2009 63

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 GEARS Shopper advertising costs $300.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed
elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.

SHOPPER CLASSIFIED ADS For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.

smissions Axi-Line dyno-tested

Tran
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64 GEARS March 2009

61shoppers109.indd 64 2/12/09 11:32:33 AM

 NEED QUALITY
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TORQUE CONVERTERS
TRANSFER CASES

WE HAVE OVER 500,000 PARTS IN STOCK

CALL 602-971-0477
getithardparts.com
WE SHIP UPS DAILY

GEARS March 2009 65

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 SHOPPER CLASSIFIED March 2009
GEARS 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
advertisements in GEARS annually (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).

RatioTek™
Valve Body Kits :(+$9(3$576,1672&.)25
8(5(/(/(/(
Easy to Install - Low Cost - Great Results
USED , OEM NEW &
-- Kits At Part Suppliers Now -- AFTERMARKET HARD PARTS

RT 4F50N
™ KNOWLEDGEABLE & COURTEOUS
SALES STAFF

Also fits AX4N FOREIGN & DOMESTIC

Billet retainers MACHINE SHOP WITH 30 YEARS

OF EXPERIENCE
your gonna love! 
,1672&.12:
Saves main booster.
$)5(50$5.(78(681*($5 5,1**($5
Includes a bypass
booster valve & $5(7$,/ :+2/(6$/(',675,%8725
6,1&(
sleeve.
&203(7,9(6+,33,1*5$7(6
836'+/)('(; /7/$9$,/$%/(
RT AX4S
800-461-5396
™

Also fits AXODE

Includes a bypass
booster sleeve.

Core
Saves main booster.

RT 4L60E™

Competency
Fix Code
WE HAVE WHAT YOU NEED
1870 Fast
Adjust 1-2 FOREIGN & DOMESTIC
shift firmness Standard Transmissions
without re- Transfer Cases With over 150,000 engine, transmission and
moving VB. internal part cores on the shelf, we have
New & Used Parts the cores you need – ready to ship today!
Rebuilt Units
RT E4OD/4R
™
*ONE CALL DOES IT ALL*
Kit fits
E40D and Las Vegas, NV Chicago, IL
4R100 800.426.8771 800.826.7403
CALL 702.649.7776 773.624.6111
3 High Tech BRIAN OR ALBERT
Regulator Valves. 702.649.6777 FAX 773.624.6660 FAX
Adjust shift firmness. 866-571-GEAR A Division of
®

4 3 2 7 aamidwestcores.com
www.ratiotek.com 626-968-2754

BUSINESS FOR SALE: Asheville, NC 888-686-9591 or Asheville.Transmissions@ block test capabilities. All in excellent condi-
– Well established ATRA transmission shop Gmail.com. tion, included are dyno tester with 392 Ford
in business for over 40 years located in the ATRA Mbr gas engine with Zoom Technology window
heart of the beautiful Smokey Mountains. based computer system, valve body cali-
Prime downtown commercial property with BUSINESS FOR SALE: California – You bration tester designed by Aidco Company
very large historic building and ample park- need to take a look at this one! 40 years of for Allison. New Allison diagnostic scanner,
ing. Shop’s vast and unobstructed 8000+ excellent business transmission & general complete paint booth system, 454 and 643
sq. ft. interior space includes multiple lifts, automotive service. Same great location, reman units, cores and inventory stock, cus-
office, restrooms, all equipment and many central California, this is not your ordinary tomer/client list. Asking $75,000 for all or will
vintage parts. Available separately, busi- shop. Large building with latest equipment, sell separately. Northwest Ohio area. Con-
ness with equipment & inventory offered at owner ready to retire. Contact (209) 602- tact Jim at (419) 215-5504. ATRA Mbr
$225,000 and land with building offered at 7250. ATRA Mbr
$765,000, or as a discounted package deal. EQUIPMENT FOR SALE: TCRS -Torque
Owner ready to retire. Buy one of the most EQUIPMENT FOR SALE: Heavy duty Converter Rebuilding System, includes:
respected businesses in the area and con- transmission dyno test business for sale, TCRS Auto-align welder, electronic balancer
tinue with its long history of success. Some designed for Allisons, heavy duty trucks and leak tester. Also includes, lathe and in-
owner financing available. Contact John and cars and any RWD units with solenoid ventory of parts. New 1999, all equipment is

66 GEARS March 2009

66classfd309.indd 66 2/12/09 12:33:20 PM

 in good working condition -$30,000. Please to live in one of the most desirable places call Brandy at (850) 729-6629. You can also
call (815) 337-1081 and ask for John. to hunt, fish, 4 wheel in USA, NOW is your email or fax your resume to tctransmission@
ATRA Mbr chance!! ATRA Mbr embarqmail.com or fax (850) 729-1529.
ATRA Mbr
POSITION WANTED: Money Maker/Cus- HELP WANTED: Seattle, Washington
tomer Producer – Center Manager position – Transmission rebuilder needed in well es- HELP WANTED: SuperFlow Technologies
sought by a leader with over 23 years in the tablished, well equipped transmission shop Group, www.superflow.com has an immedi-
transmission industry. Talented, indepen- of over twenty years. Rebuilding and diag- ate need for a Sales Executive. Sales expe-
dent and up to date with what it takes to nostic experience required. Monday through rience in capital equipment market a must.
make a modern day shop run smoothly and Friday, benefits include paid vacation, holi- Degree in automotive field or equivalent
make profit. Experience includes rebuilding, days and health insurance; pay $30 to $35 work experience preferred. Mechanically
diagnosing, and shop ownership. Contact dollars per hour depending on experience. and electrically inclined, ability to read blue
Michael Ryan at (928) 706-6453 for more Contact Mark at (206) 624-1859. prints. Must be able to travel. Contact: hr@
information. ATRA Mbr superflow.com, Fax: (515) 254-1656.
ATRA Mbr
HELP WANTED: Colorado Springs- Trans- HELP WANTED: Quality Control/Training
mission Rebuilder for well established, Supervisor needed for a high volume trans- HELP WANTED: TransTeam Employment
reputable shop. Must have five plus years mission remanufacturing company located USA, The National Employment Headquar-
rebuilding experience in domestic, import, in the Midwest. Extensive transmission ters for the transmission industry wants you!
transfer cases, automatics and manual shift. knowledge is needed, with experience in di- We offer a low cost internet recruiting ser-
Strong diagnostic skills, including electrical agnostics and rebuilding. Excellent position vice for our registered transmission shop
are required. Certifications are favorable. with benefits and growth potential. Please owners and deliver nationwide job opportu-
Must be a team player, clean cut, and pos- send resume to: [email protected] regard- nities to our registered employees. Always a
sess a higher than standard work ethic. Full ing BB# 0109. ATRA Mbr free service to all industry employees. Visit
benefits package for the right person. Mon- our web site www.transteam.com 24 hours
Fri work week. Pay DOE. Please contact HELP WANTED: Twin Cities Transmission a day, 7 days a week to see how it works
(719) 494-8098 –leave message, or fax re- in Niceville, Fl is looking for a SwingMan. or call (888) 412-TEAM (8326). We make it
sume to: (719) 494-8097. If you ever wanted Medical available! We work 5 days. Please, easy to relocate! ATRA Mbr

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GEARS March 2009 67

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 ADVERTISERS
Name Page Name Page

ATI Performance Products .......................................... 7 Precision International ............................................... 21

www.atiperformanceproducts.com www.transmissionkits.com
ATRA ...........................................................31, 41 & 43 Raybestos Powertrain ................................................. 3
www.atra.com www.raybestospowertrain.com
Borg-Warner Automotive ........................................... 45 Slauson Transmission Parts ...................................... 41
Certified Transmission ............................................... 27 www.slauson.com
www.certifiedtransmissions.com Sonnax Industries.................................................... IFC
EVT Parts .................................................................. 23 www.sonnax.com
www.evtpaarts.com SuperFlow Technologies Group ................................ 33
First National Merchant Solutions ............................. 31 www.superflow.com
www.fnms.com Superior Transmission Parts ......................................11
Heffernan Group ........................................................ 37 www.superior-transmission.com
www.heffgroup.com Transmission Specialties ........................................... 29
Jasper Engines & Transmissions ............................ IBC www.transmission-specialties.com
www.jasperengines.com Transtar Industries, Inc. ............................................... 9
Life Automotive Products Inc..................................... 17 www.transtarindustries.com
www.smartblend.com TransTec By CORTECO............................................ 13
LUBEGARD® By International Lubricants, Inc. ..... OBC www.transtec.com
www.lubegard.com Whatever It Takes Transmission Parts, Inc. .............. 19
Power Pusher By Nu-Star, Inc. ................................. 43 www.wittrans.com
www.powerpusher.com ZF Sales and Service NA, LLC ................................. 15
Precision European Inc. ............................................ 67 www.zf.com/na
www.peius.com

CALENDAR
y ATRA Technical Seminar Schedule
3/21/09 Houston, TX 5/30/09 Des Moines, IA
3/21/09 St. Louis, MO 5/30/09 Dallas, TX
3/28/09 Boston, MA 6/13/09 Vancouver, BC
2009

4/4/09 Minneapolis, MN 8/1/09 San Antonio, TX

4/18/09 Salt Lake City, UT 8/8/09 Los Angeles, CA
4/25/09 Fremont, CA 8/22/09 Cincinnati, OH
5/2/09 Toronto, ON 8/29/09 Chicago, IL
5/9/09 Denver, CO 10/17/09 New York, NY

Check ATRA.com for more dates and

locations to come!

68 GEARS March 2009

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