Jf506e 2

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Jatco 5 Speed 1
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2005 ATRA. All Rights Reserved. Printed in U.S.A.

Jatco 5 Speed
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Jatco 5 Speed 3
Table Of Contents
Transmission Diassembly ............................................................................ 4
Front Pump ................................................................................................. 16
Reverse/High Clutch Drum ......................................................................... 18
Direct Clutch Drum ..................................................................................... 22
Low Clutch Drum ........................................................................................ 26
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Planetary Gearsets ...................................................................................... 29
Transfer Gear/Reduction Gear..................................................................... 30
Rear Cover................................................................................................... 33
Valve Body .................................................................................................. 35
Transmission Case Assembly ....................................................................... 44
Bearing Race Location ................................................................................. 64

Jatco 5 Speed
Transmission Case: Disassembly

1. Remove the side cover.
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2. Remove the bolt holding the internal harness connectors and disconnect the
(2) internal harness connectors.

Jatco 5 Speed 5
3. Remove only the valve body bolts shown and remove the valve body. To get
to the bolt under the wiring (arrow) disconnect the solenoid.
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Jatco 5 Speed
4. Remove the case connector retaining clip and remove the internal wiring
harness.
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5. Remove the valve body to case seals

Jatco 5 Speed 7
6. Remove the (22) bellhousing to case bolts.

7. Lightly tap the converter housing with a plastic hammer to seperate the
halves.
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8. Remove the differential.
9. Remove the filter, pump O-ring and the input shaft O-ring.
10. Remove the front pump and the gasket.

11. Remove the input shaft.

Jatco 5 Speed
12. Remove the reduction gear assembly.

13. Remove the reduction sun gear assembly.
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14. Remove the direct clutch.
15.. Remove the reduction brake band and the band anchor bolt.
16. Remove the (16) rear case cover bolts. Note the O-rings on the two larger
bolts.

Jatco 5 Speed 9
17. Remove the 2-4 piston and the sealing rings from the rear cover.
18. Remove the 2-4 accumulator assembly from the rear cover.
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19. Remove the (3) bolts holding the one way clutch inner race to the case. Note
the O-rings on the larger bolts.
20. Remove the oil pipes.

10 Jatco 5 Speed
21. Remove the speed sensor bolts.

22. Remove the speed sensor and the rear cover to main case seal.
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23. Remove the direct cluch accumulator assembly.
24. Remove the 2-4 clutch piston return spring.
25. Remove the Rev/High clutch drum bearing.

26. Remove the Rev/High clutch drum.

Jatco 5 Speed 11
27. Remove the clutch hub to Rev/High clutch drum bearing.

28. Remove the clutch hub and the clutch hub to sun shell bearing.
29. Remove the sun shell and the sun shell to planet bearing.
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30. Remove the front planet and the planet to sun gear bearing.
31. Remove the sun gear and the sun gear to rear planet bearing.
32. Remove the rear planet and the rear planet to ring gear bearing.

12 Jatco 5 Speed
33. Remove the rear ring gear and the ring gear to Low drum bearing.
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34. Remove the Low Drum and the Low drum to case bearing.
35. Remove the 2-4 clutches (3) and steels (4). Note: There are (2) 2-4 steel
plates back to back next to the snap ring.

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For this next step a special tool needs to be used. A speicial tool can be
fabricated out of a piece of flat steel or a piece of bar stock. A long bolt or a
length of all-thread is required as well.
The bar stock needs to 7-7 1/4 inches long with a hole drilled in the middle
large enough for the bolt or the all thread to pass easily through the tool.
The long bolt shown is from Kent-Moore tool # J-23327-1.
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36. Using the special tool compress the low/reverse piston and remove the
retaining snap ring. Note: The opening of the snap ring has curved ends
and only fits into the case one way.

14 Jatco 5 Speed
37. Remove the low/rev clutches (6) and steel plates (7). Note the position of the
dished plate for reassembly.
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38. Remove the low/rev sprag retaining snap ring and the low/rev sprag. Note
the position of the snap ring opening for reassembly.
39. Remove the servo cover snap ring.

40. Remove the servo cover by blowing shop air into the port shown.

Jatco 5 Speed 15
WARNING!
On the right is the original servo cover that was removed from this
transmission. This cover was stuck in the bore. No amount of air pressure
was going to force this cover out of the bore. Breaking the cover apart was
the only solution.
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The Cause
The problem is corrosion between the lip of the servo cover and the
transmission case.
The Solution
Prior to assembly run a bead of silicone around the servo just below the lip.
This will keep out moisture and prevent corrosion.

16 Jatco 5 Speed
Subassembly Rebuild Procedure
Front Pump: Disassembly And Assembly
1. Remove (8) 5mm allen bolts and split the pump halves apart.
2. Remove the pump gears from the body.
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3. Clean and dry all pump components.
4. Inspect the pump gears and the pump pocket for wear and scoring.
5. Inspect the stator support half for wear and scoring. Inspect the bushing for
wear.

Jatco 5 Speed 17
6. Install a new pump bushing and seal. Note: The step in the bushing is in
stalled towards the gear.
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7. Lightly lube the pump pocket and install the pump gears. Use a small
amount of assembly gel to keep the pump gears centered in the pocket.
8. Install the stator support onto the pump body. Install the (8) 5mm bolts and
tighten them to 96 in. lbs.

18 Jatco 5 Speed
Reverse/High Clutch Drum: Teardown And Assembly
1. Remove the reverse clutch retaining snap ring and the reverse clutch
pressure plate.
2. Remove (2) reverse clutches and (2) reverse steel plates.
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3. Remove the direct clutch retaining snap ring and pressure plate.
4. Remove the (5) direct clutches and (5) direct steels.

Jatco 5 Speed 19
5. Using a suitable press, compress the piston return spring and remove the
retaining snap ring.
6. Remove the retainer, return springs and the pistons from the drum. Remove
and discard the piston seals.
7. Clean and dry all rev/hi clutch drum parts.
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Caution
Carefully inspect the reverse piston. The piston can crack. The crack is very
difficult to see. If the clutches in the drum are burnt, ALWAYS replace the
reverse piston. The Mazda part number is FP03-19-480.

20 Jatco 5 Speed
8. Install new seals on the pistons and install the pistins into the drum.
9. Using a suitable press, compress the spring retainer and install the
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10. Install the (5) direct clutches and (5) steel plates.
11. Install the pressure plate and the reatining snap ring. Direct clutch
clearance should be .031-.043 in. and is adjusted by changing the pressure
plate.

Jatco 5 Speed 21
12. Install the (2) reverse clutches and (2) steel plates.
13. Install the reverse pressure plate and the retaining snap ring. Reverse
clutch clearance should be .020-.030 in. and is adjusted by changing the
pressure plate.
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14. Install (3) sealing rings onto the rear cover and place the drum onto the rear
cover to air check the clutch drum.

22 Jatco 5 Speed
Direct Clutch Drum: Teardown and Assembly
1. Remove the direct clutch retaining snap ring and pressure plate.
2. Remove the (4) direct clutches and (4) steel plates.
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3. Using a suitable press, compress the spring retainer and remove the
4. Remove the retainer, return spring and the piston.

Jatco 5 Speed 23
5. Remove the sprag retaining snap ring and the sprag retaining washer.
6 Remove the sprag and the needle bearing.
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7. Clean and dry all direct clutch drum components.
8. Inspect the sprag race and the sprag elements for wear and scoring.
9. Install the bearing and the sprag into the drum. Note: The lip on the sprag
faces up.
10. Install the retainer and the snap ring.

24 Jatco 5 Speed
11. Install new seals onto the piston. Lightly lube the seals and install the
piston into the drum.
12. Using a suitable press, compress the return spring and install the retaining
snap ring.
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13. Install (4) direct clutches and (4) steel plates.
14. Install the direct clutch pressure plate and the retaining snap ring. Direct
clutch clearance should be .040-.080 in. and can be adjusted by changing
the pressure plate.

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15. Install the inner sprag race into the sprag to air check the drum.
16. The sprag race should freewheel counter clockwise.
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26 Jatco 5 Speed
Low Clutch Drum: Teardown and Assembly
1. Remove the retaining snap ring and the low clutch pressure plate.
2. Remove the (7) Low clutches and (7) steel plates.
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3. Using a suitable press, compress the spring retainer and remove the snap
ring.
4. Remove the retainer, return spring and the low piston.

Jatco 5 Speed 27
5. Clean and dry all low clutch drum components.

6. Inspect the sprag race on the drum for wear and scoring.
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7. Install new seals on the piston and spring retainer.
8. Lightly lube the piston and install the piston, return spring and retainer into
the low drum.
9. Using a suitable press, compress the return spring and install the snap
ring.

28 Jatco 5 Speed
10. Install the dished spring plate as shown.
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11. Install (7) low clutches and (7) steel plates.
12. Install the low pressure plate and snap ring. Low clutch clearance should be
.044-.051 in. and is adjusted by changing the pressure plate.

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Planetary Gear Sets
Inspect the planetary gear sets for gear wobble and broken or cracked teeth.
If any are damaged or worn the planetary gear set must be replaced.
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30 Jatco 5 Speed
Transfer Gear / Reduction Gear: Teardown And Assembly
1. Remove the lock nut on the transfer shaft.

2. Using a suitable press, support the idler gear and press the shaft through
the bearing race and the reduction gear.
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3. Clean and dry all transfer gear/reduction gear components.
4. Inspect the idler gear (large gear) bearings for wear and scoring.
5. Inspect the reduction gear planetary gear set for gear wobble and broken or
cracked teeth.

Jatco 5 Speed 31
6. Place the idler gear onto the reduction gear shaft. Using a sleeve start the
bearing onto the shaft.
7. Place the reduction gear onto the shaft. Using a sleeve start the gear onto
the shaft.
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8. Press the gear and the bearing into place.
9. Press the bearing race into place.

32 Jatco 5 Speed
10. Tighten the nut onto the reduction shaft until 5-15 in. lbs. of turning torque
is obtained.
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11. Stake the nut into place.

Jatco 5 Speed 33
Rear Cover: Teardown And Assembly
1. Remove the piston and discard the seals.

2. Remove the accumulator cover retaining snap ring.
3. Remove the accumulator cover, the spring and the piston.
4. Remove the three sealing rings.
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34 Jatco 5 Speed
5. Clean and dry all rear cover components

6. Inspect the accumulator borde for wear. The bore should be smooth and
free from any scoring.
7. Install new seals on the 2-4 piston. Lightly lube the seals and install the
piston into the rear cover.
8. Install (2) new teflon sealing rings onto the accumulator piston and install
the piston into the rear cover.
9. Install the spring and the accumulator cover with a new O-ring.
10. Install the retaining snap ring.
11. Install (3) new sealing rings with the V-cut as shown.
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Jatco 5 Speed 35
Valve Body: Teardown And Assembly
There are two vavle body configurations for this transmission. The Mazda
valve body and the Volkswagen/Jaguar. These valve bodies are NOT
interchangeable. The Jaguar valve body is the same as the Volkswagen
except that it has one less checkball. Caution: Some of the valves in both
valve bodies are teflon coated. DO NOT use abrasives on these valves. If the
valves are worn or become sticky in the bores the valve body may need to be
replaced.
Mazda
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VW/Jaguar

36 Jatco 5 Speed
Mazda Valve Body
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ID Description
1 Modifier Accumulator Valve
2 Pressure Modifier Valve
3 Torque Converter Pressure Regulator Valve
4 Throttle Accumulator Valve A
5 Accumulator Valve A
6 Throttle Accumulator Valve C
7 Accumulator Control Valve C

Jatco 5 Speed 37
Mazda Valve Body
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ID Description
1 Failsafe Valve
2 Shift Valve A
3 Reverse Inhibit Valve
4 Neutral Control Valve
5 Accumulator Switch Valve
6 Pilot Valve
7 Manual Valve
8 Neutral Shift Valve
9 TCC Control Valve
10 Shift Valve B
11 Plug

38 Jatco 5 Speed
Mazda Valve Body
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ID Description
1 Shift Valve C
2 Low Clutch Accumulator
3 High Clutch Accumulator
4 Throttle Accumulator B
5 Accumultor Valve B
6 Pressure Regulator Valve
7 Line Pressure Relief Valve
8 Reduction Timing Valve
9 Reduction Reducing Valve

Jatco 5 Speed 39
Mazda Checkball Locations
4 Steel Checkballs
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5 Plastic Checkballs

40 Jatco 5 Speed
Volkswagen/Jaguar Valve body
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ID Description
1 Modifier Accumulator
2 Pressure Modifier Valve
3 Torque Converter Regulator Valve
4 Throttle Accumulator Valve A
5 Accumulator Control Valve A
6 Unknown
7 Unknown

Jatco 5 Speed 41
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ID Description
1 Shift Valve C
2 Low Clutch Accumulator
3 High Clutch Accumulator
4 Throttle Accumulator
5 Unknown
6 Accumulator Control Valve B
7 Unknown
8 Pressure Regulator Valve
9 Line Pressure Relief Valve
10 Reduction Timing Valve
11 Reduction Reducing Valve

42 Jatco 5 Speed
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ID Description
1 Shift Valve A
2 Reverse Inhibit Valve
3 Neutral Control Valve
4 Accumulator Switch Valve
5 Pilot Valve
6 Manual Valve
7 Neutral Shift Valve
8 TCC Control Valve
9 Shift Valve
10 Failsafe Valve

Jatco 5 Speed 43
4 Steel Checkballs
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5 Plastic Checkballs
Jaguar Has No Checkball Here

44 Jatco 5 Speed
Transmission Case: Assembly
1. Remove the manual lever detent spring. Drive out the (2) roll pins holding
the rooster comb and park linkage. Remove the manual linkage retaining
bolt.
2. Replace the manual lever seal and reinstall the manual linkage components.
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Note: Before installing the retaining bolt be sure to aligin the park linkage.

Jatco 5 Speed 45
3. Place a 1 1/4 in. 12 point socket over the splines to check the output gear
turning torque. Turning torque should be 5.6- 11.5 in. .lbs.If not as
specified replace the output gear bearing assembly.
4. Install (2) low clutch drum sealing rings. Retain with assembly gel.
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5. Install (2) sealing rings onto the one way clutch inner race.
6. Install new O-rings onto the (2) large bolts and install the sprag race into
the case. Torque the bolts to 24-28 ft. lbs.

46 Jatco 5 Speed
7. Install the low/reverse sprag into the case with the smooth side facing up.
8. Install the retaining snap ring into the case. Note the location of the snap
ring opening.
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9. Install the low/reverse clutches (6) and steel plates (6).
10. Install the dished plate as shown.
Top

Jatco 5 Speed 47
11. Install the low/reverse return spring seat and spring.

12. Install the low/reverse piston and piston housing.
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13. Using the special tool made during transmission teardown, compress the
low/reverse piston housing and spring assembly.
14. Install the retaining snap ring. Note the location of the snap ring opening.
15. Using assembly gel, install the low clutch to case bearing on the low drum.
16. Using a twisting motion install the low drum down into the case. The drum
should feewheel counterclockwise.

48 Jatco 5 Speed
17. Install the bearing down into the drum and stick the bearing to the rear ring
gear with assembly gel. Install the ring gear down into the drum.
18. Install the bearing down into the ring gear and stick the race to the rear
planet with assembly gel. Install the planet down into the ring gear.
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19. Install the sun gear to planet bearing down into the planet. Install the sun
gear into the planet with the smooth surface facing down.
20. Stick the front planet to sun gear bearing onto the planet using assembly
gel and install the planet down onto the sun gear.

Jatco 5 Speed 49
21. Install the bearing onto the planet and stick the race onto the sun shell with
assembly gel. Install the sun shell down onto the planet.
22. Install the (3) 2-4 clutch plates and (5) steel plates.
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23. Install the high clutch bearing race onto the sun shell and stick the high
clutch hub bearing to hub using assembly gel.
24. Install the high clutch hub to high clutch race down into the hub. Stick
the bearing to the high drum with assembly gel and install the high drum
down onto the hub.

50 Jatco 5 Speed
25. Install the high clutch to rear cover bearing down into the drum.
26. Install the 2-4 piston return spring.
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27. Install new seals on the accumulator piston and cover and Install the
accumulator assembly into the case.
28. Install the speed sensor wiring loom into the case and install the input
speed sensor. Install the case to rear cover seal (arrow).

Jatco 5 Speed 51
29. Install the (3) oil tubes
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30. Using an H gauge check the endplay. Place the gauge on the transmission
case and set the plunger down onto the high clutch bearing.

52 Jatco 5 Speed
31. Flip the H gauge over onto the rear cover. When the washer is in place the
end clearance should be .010 - .020 in. and is adjusted by changing the
bearing race.
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Jatco 5 Speed 53
32. Place the end cover onto the transmission case. There will spring tension on
the cover. Tighten the end cover bolts down evenly and torque the bolts to
14 - 16 ft. lbs.
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33. Replace the O-rings on the larger bolts.

54 Jatco 5 Speed
34. Install the speed sensors and the TFT sensor into the case.
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35. Install the servo into the case. Note: It is very important to loosen the lock
nut on the servo prior to installation.

Jatco 5 Speed 55
36. Install the direct drum down into the case.
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37. Install the band down into the case. While holding the band in position,
screw the band anchor bolt, from the outside of the case, into the slot in the
band. Note: Add thread sealer to anchor bolt prior to installation to prevent
leaks.

56 Jatco 5 Speed
38. Install the sun gear bearing down into the center of the reduction drum and
secure the race to the sun gear with assembly gel. Install the sun gear down
into the reduction drum.
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39. Install the reduction gear assembly down into direct clutch. The reduction
gear assembly is all the way down into the drum when the reduction gear is
flush with the output gear.
40. Install (3) new sealing rings onto the input shaft and install the input shaft
into the transmission.

Jatco 5 Speed 57
41. Install a new front pump gasket and install the front pump. Torque the front
pump bolts to 14-16 ft. lbs.
42. Install a new input shaft O-ring, front pump O-ring and a new filter.
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43. Install the final drive.
Jaguar AWD
VW/Mazda

58 Jatco 5 Speed
44. Thouroughly clean and dry the two magnets and install them into the case.
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45. Flat file the bell housing to knock down any high spots prior to installation.
46. Lightly lube the pump O-ring and apply a bead of sealer to the bell housing.
Install the bell housing onto the transmission case. Tighten all bolts to
20-22 ft. lbs.

Jatco 5 Speed 59
47. Install two case to valve body seals
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48. Air Check passages.

60 Jatco 5 Speed
Valve Body Installation
47. The manual valve cannot be seen during valve body installation. This makes
the installation rather tricky
The Easy Way
Place the manual linkage in the manual low position.
Slide the manual valve down into the valve body and lower the valve body
onto the transmission case. Install two bolts only hand tight.
When the manual valve is engaged onto the linkage the manual valve can be
seen sticking out of the valve body approx. 3/8 in. and will move in and out
while rotating the manual lever.
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Jatco 5 Speed 61
48. Connect the speed sensor harness and the solenoid harness plug-ins.
Install the valve body bolts. It may be necassary to unplug the solenoid to
install the valve body bolt below the wiring harness (arrow). Tighten valve
body bolts to 60-72 in. lbs.
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62 Jatco 5 Speed
49. Using a new side cover gasket, install the side cover.
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50. Band adjustment: Loosen the lock nut several turns. Screw the band adj
uster in until it bottoms out and back off 2 1/2 turns and tighten the lock
nut down. Note: A 14mm crows foot may need to be modified to fit properly
over the lock nut.

Jatco 5 Speed 63
51. Install new seals on the servo accumulator piston and the servo cover.
Assemble the servo cover and install the snap ring.
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52. Place a bead of silicone around the upper lip of the servo cover (this will
prevent corrosion) and install the servo cover into the transmission.

64 Jatco 5 Speed
Bearing And Race Locations
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Jatco 5 Speed 65
Bearing And Race Locations
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66 Jatco 5 Speed
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Jatco 5 Speed 67
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68 Jatco 5 Speed
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Jatco 5 Speed 69
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70 Jatco 5 Speed
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Jatco 5 Speed 71
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72 Jatco 5 Speed
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Jatco 5 Speed 73
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74 Jatco 5 Speed
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What are the main components of the transmission discussed in the document?

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What are the steps involved in disassembling the transmission case?

What are the steps involved in disassembling the transmission case?

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2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Transmission Diassembly ............................................................................ 4

Front Pump ................................................................................................. 16

Reverse/High Clutch Drum ......................................................................... 18

Direct Clutch Drum ..................................................................................... 22

Low Clutch Drum ........................................................................................ 26

Transfer Gear/Reduction Gear..................................................................... 30

Valve Body .................................................................................................. 35

Transmission Case Assembly ....................................................................... 44

Bearing Race Location ................................................................................. 64

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Transmission Case: Disassembly

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

6. Remove the (22) bellhousing to case bolts.

10. Remove the front pump and the gasket.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

12. Remove the reduction gear assembly.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

20. Remove the oil pipes.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

21. Remove the speed sensor bolts.

25. Remove the Rev/High clutch drum bearing.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

27. Remove the clutch hub to Rev/High clutch drum bearing.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

39. Remove the servo cover snap ring.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Subassembly Rebuild Procedure

Front Pump: Disassembly And Assembly

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Reverse/High Clutch Drum: Teardown And Assembly

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Direct Clutch Drum: Teardown and Assembly

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

Low Clutch Drum: Teardown and Assembly

2005 ATRA. All Rights Reserved. Printed in U.S.A.

5. Clean and dry all low clutch drum components.

2005 ATRA. All Rights Reserved. Printed in U.S.A.

10. Install the dished spring plate as shown.

2005 ATRA. All Rights Reserved. Printed in U.S.A.