Playing with FireA New Look at                                                                                    SPEAKERS...
OEM to GM & Ford in Wet Friction & Torque Converter Products.                         From the world’s largest independent...
A New Look at Standardsobvious pitting on planets/gears.     With standards, the wear couldseem trivial to your automatic ...
units with early shift tower designs,can be repaired inexpensively, withoutremoving the transmission.Fluids     It used to...
Build your own convertersand GROW your business!ATI’s CW3                                                                 ...
While we regret not meeting you in person, we’d like to offer                                                             ...
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A New Look at Standards

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A basic of overview of standard transmission rebuilding techniques.

Shown courtesy of Gears Magazine.

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A New Look at Standards

  1. 1. Playing with FireA New Look at SPEAKERStandards by Jon Rodriguez members.atra.com www.atra.comI n every transmission shop there are many learning curves to go through: maintaining the shop,R&R, building, differential work, diag-nosing, managing — there’s alwayssomething on the list called “Things toKnow in a Transmission Shop.” Standard transmissions: Where arethey on your list? For a lot of trans-mission guys, standards are somethingyou R&R for a clutch or replacement;nothing more. Why is that? Why wereso many technicians scared into stayingaway from the stick shift? Welcome to this edition of Playingwith Fire. With a little help from theguys at Anaheim Gear in Anaheim, CA,I’ve collected some of the most com-mon tips you should consider beforerebuilding standard transmissions.When Not to Build Sometimes it just makes goodsense to avoid working on a standardtransmission: If a standard-equipped vehicleshows up on a flatbed with a bucket ofparts that were picked up off the street Figure 1where it stopped moving, that’s one you until you have the unit out of the car age units. Search craigslist.org, ebay.probably don’t want to try to rebuild. and apart on the bench. So it’s impor- com, and other online classified web If a standard fails because it ran out tant that the techs and the managers sites for parts or cores.of oil, that’s another one you won’t want are on the same page when it comes to Remember, most vehicles withto touch. The reason? The parts you’ll options for repairs. stick shifts are budget vehicles. Doingneed will cost more than a replacement. Obviously a replacement is a worst some extra work to keep costs down How should you deal with those case scenario when it comes to cost, can make the difference between get-situations? Have a core to rebuild and not to mention the additional clutch ting the job and having the vehicleexchange, find a good used unit, or get and chassis costs. You don’t want to towed away.a rebuilt exchange unit. scare the customer away with the worst case numbers, but the possibility of TeardownSelling the Job the job getting to that level needs to be This can make or break the job. Standards can be tough on a man- explained. Standards wear parts differently thanager. That’s because there’s really no Do your homework; call your local automatics do. It’s usually pretty obvi-way to know what’s going on inside wrecking yards for cores or low mile- ous with automatics: burnt clutches,26 GEARS September 2010
  2. 2. OEM to GM & Ford in Wet Friction & Torque Converter Products. From the world’s largest independent manufacturer of torque converters and the world’s largest manufacturer of combined wet and dry friction products.Exedy dominates the OEMmarket in the world over-fact! CORE TECHNOLOGYExedy is a powertrain specialist and tier one supplier FRICTIONto the automotive industry world wide. Exedy’s Development of çproducts range: From wet & dry friction material, torque the highest quality FRICTION MATERIALconverters, complete transmission systems for highway,off-highway and industrial applications. that can demonstrate the World’s top level =FRICTION TECHNOLOGY performance.Exedy is responsible to all 11 OE automotive vehiclemanufacturers in Japan. For the conception ofpowertrain product requirements and needs. ç VIBRATIONIn the US Exedy supplies Ford-GM-Chrysler, powertrain We haveneeds such as torque converters, wet friction materialand standard clutch systems. =DAMPER TECHNOLOGY developed the most efficient Damper that can absorb vibrationWorldwide Exedy has evolved through developing from the engine moreand patenting the core technologies such as friction, FLUID than ever.vibration and fluid technology. DYNAMICS Having analyzed ç the fluid dynamicsExedy products have been recognized by vehicle =FLUID TECHNOLOGY inside Torque Converter,manufacturers all over the world. As a premium brand EXEDY has successfullyin Japan, Exedy products are valued so highly that developed the mostour products are renowned all over the world by car efficient product in the market.manufactures. Exedy continues to hold a large share of Excellent Capacity forthe OEM market both domestically and internationally. Development for Fluid Technics www.exedyusa.com Available through all authorized Transmission WDs & Jobber Shops
  3. 3. A New Look at Standardsobvious pitting on planets/gears. With standards, the wear couldseem trivial to your automatic eyes, butthat small amount of wear will bite youwhen the transmission is back in thevehicle. This input and cluster from a T-56(figure 1) appear to be in good shape.No obvious signs of galling or pittingon the gears. But pay attention to thebluing between the gear teeth. That’sa sign of overheating. When the metalgets that hot, it weakens the gears andcauses noise in the transmission. If you overlook this type of failureduring your initial inspection, it’s notonly going to require complete disas-sembly of the unit, but it could add ahefty parts cost that nobody ever men-tioned to the customer beforehand.Soft Parts Standard transmission rebuildkits are much simpler than automatictransmission kits. A couple seals, someO-rings and gaskets, bearings, and Figure 2maybe synchros are all that’s included have most of the job done. as a shear key; it needs to slip beforein your kit. Suppose you’re working on a high something else breaks. Synchronizers are usually optional performance vehicle. Should you installwhen buying kits, so make sure to tell a high performance clutch? Be careful! Engine Missesyour supplier if you’d like brass includ- Performance clutches do provide stron- Engine misses can cause a clat-ed. Brass synchros don’t necessarily ger holding power, but they can reduce ter or rattle in the transmission. Thishave to be replaced with every rebuild. reliability and functionality. is especially true for heavy duty truckIf the synchros are paper clutch lined, Usually the modulation (amount of applications: Heavy duty clutches havethen yes, replace them. If they’re solid clutch pedal travel between disengage- stiff damper springs that can’t absorbbrass and in good shape, they can be ment and engagement) is dramatically the vibrations coming from a poorlyreused. Figure 2 shows the three main shorter with high performance clutches. tuned engine.areas to check on a synchro. Think NASCAR; they’re either roast- The misfire causes a back-and- If the synchro is worn where it ing the tires coming out of the pits or forth power delivery that forces therides on the cone of the gear, inspect the the engine stalls. Is that what you want gears to bounce against each other,cone closely for any grooves or uneven your customer doing with his freshly causing noise and premature gear fail-wear patterns. If the cone is worn, rebuilt transmission? ure.you’ll need to replace the gear, too. Another feature sacrificed with high performance clutches is dampen- Shifter LinkageHard Parts ing. Those little springs on the inside When test driving a standard, It may surprise you how inexpen- diameter of the clutch disc absorb always check the shifter for looseness.sive some big parts are. If you can’t normal vibrations transmitted by the Just about every standard-equippedfind a sacrificial core, call your sup- engine. If the dampeners are omitted vehicle has some sort of soft linkagepliers or specialty rebuilders to see or too stiff, normal engine vibrations that can wear and not allow the shifterwhat’s available. Those rebuilders have can turn into violent shudders during to engage the gears completely.machinery that can repair worn bearing engagements. That can cause broken One of the most common misdi-races or shaft tips for a fraction of the gear teeth and busted shafts. agnoses is on rear wheel drive Toyotacost of a new one. This is especially common with trucks. There’s a donut shaped seat Honda/Acura and Mitsubishi perfor- that the shifter ball sits into. When theThe Clutch mance applications. Are there perfor- seat deteriorates, the shifter becomes Typically, you’ll be replacing the mance gears and shafts? A few, but the loose and will only partially engage theclutch during the transmission overhaul parts are expensive, and all that ends transmission into gear, especially third.unless it was replaced recently. It just up doing is moving the weak link to the Other vehicles, such as Saturnsmakes sense considering you’ll already next gear or shaft. Think of the clutch with bad cables and GM New Venture28 GEARS September 2010
  4. 4. units with early shift tower designs,can be repaired inexpensively, withoutremoving the transmission.Fluids It used to be simple when it cameto fluid use in standards and transfer 2400 Latigo Ave Oxnard CA, 93030cases. There was one option: gear oil. MEMBER PRICE $50.00 NewIn the 90s it became slightly morecomplicated, with the introduction of NON MEMBER $60.00 rd the lter. d remov ual lev e manu er. Intro ro ntr lts and discar nual lever anstandards and transfer cases that used x an lter bo ard on the m ove 3 tw 3. Rem the tabs ou a s nt ents 4. end 4 Benautomatic transmission fluid. e f Co Table o r Book Today there are over a dozen dif- Chr ys le ............ 9 .......... ............91 ....90 90 9 91 ........... . ... ..ferent fluids available for manual trans- ction Op io tio .. ... ..... ..... .................. .. ..... . 68RFE ion ............. ........... ...... .................. ....93 Introdu peration ...... ... ...... ....... ... ... ... .. ... . ... ... . . . . ... ... .. .......... 93 ... ... ... ... .. ... ... .................. ....... ......9 . ...... 92 ......92 ... 94 94 Clutch ................. ............. .missions. Just about every manufac- l . .. . . ... .. ... ... . .......... ... 6 .......96 .. ...... Oil Leve 4 .............. .. .................. ................. ....97 . . .. .. . .... ... . 7 Mopar +4 . n Por rts .. ... .................. .............. s . . e esti ting Po . .. ....... ... . ... .. 99 sure T .. .... ... . .... .......... ................... Pres ....... ..turer has its own formula, and using ... ... ..... ..................1 . 00 ............ ............ ................. ...............101 ... ... . ............ .................. ............. 102 . nyms ... ... ol Acro es ......an incorrect fluid can cause subtle, yet .......... ....106 Scan To arn Procedur .................. ................. .108 . e Le es ...... ......... . Quick arn Procedur .................. ............ ..110 ive Lee ... ......... ........... ................ 11 . Dr ls ...... ............annoying problems. Te st Too ns ...... .................. . ...... ...............1 tio . 2 escrip tors ............ .......11 Code D Connec rcuits ......... .................. ....113 e and ... Modul ound Ci ................ ................... .114 and Gr ............ The best choice is to use the OEM Power . . ... ........... ....... ... Sensor .................. e Index ........ ...........116 . ...... Range ts m n ...... . 117 r Circui Clutch Volu ................... ............ 18 Senso ing .. .......... e tand ng ...... .1specific fluid. Sure, it may cost more, Unders Switch Wiri .......... .................. 20 . Pressur e ............ ..................1 1 . ............ ... 12 ntrol.. n ............... .................. 3 len oid Co riptio ......... ...... 12but using the correct fluid will give you Shift So p Valve Desc .................. f . ............ ... 124 m ... .......... ... Oil Pu Body ... .................. .................. ....125 . Valve dy...... ...... Upper p lve Bo ........... .................. . ...... Va Play .....126 Lower ar End ............piece of mind and it’ll help the trans- o ndplay . d and Re tput Shaft E n................ ..............127 Front r o . ring Ou d Positi ............ Measu Location an ................... Bearin g ............ .......128mission shift just the way it did off the ............ 30 .......... ................1 . .. ... 131 10 AS68R C rt ...... Chart .................. serv ed © 20 ication c ... ...... 13 2 hts Re nd Appl on peratio .................. ..133 All Righshowroom floor. and Ba tion and O n ... 3 ATRA Clutch Descrip .......... ......... ............ ..134 4 Solenoid formation ... ............ 35 In ......... ............ ...........135 Service As with anything in life, the more ... ... . . ... ................... ...........136 .......... ps ...... ...... . ...... 37 37 Over haul Ti on ............... ..................... ..............1 ... e Pist vel..... .....138 13 B2 Brak Clutch Tra dy ...... .142you practice, the better you become. ng lve Bo v ... 1 Checki and Va .................. n tches ......... . re Swi ... , Pressu . ............ Solenoid scription ......Standards aren’t going to come into Code De © 2009 ATRA. Rights All e d. Reserve s reta ) sensor in ing bo n lt andyour shop every day, so your prac- re (TFT . peratu p ra dy id Tem the valve bo d Te ion lu sio Fl or issi n smissio e or from th h e Tran e TFT sens ove thtice may come in fits and starts. But th 6. Rem et. Remove bracke oids. he solen nect thresources are available to help you the wi res to the n ds solenoid and di n scon lor ofalong. 5. Note the co N90 9 Call Now n /LtGr N283 Lt Blu/ N282 ht Blk/W Take advantage of the shops that N91 N93 Grn/Gy N92 Y/PL R/Blu / nspecialize in standards by buying Brn/Gr the y off t lve bod the va h lly liftparts and asking for help. Chances are b dy to lve body 12 valve ca b o case bolts an o d carefu ve thethey’ve seen your problem and can e ove 7. Rem case. (800) 428-8489 ahelp get your customer’s vehicle back A=28m A=2 m 21mm B=21m B=21on the road the first time. m C=16m 1 N88 N89 Wht Blk 010 ed © 20 ghts h Reserv All Rig ATRAGEARS September 2010 29 0 d © 201 eserved
  5. 5. Build your own convertersand GROW your business!ATI’s CW3 CW3 Converter Welding Machine Produces a perfectlyConverter perpendicular, beautifully welded, perfectly true, leakproof converter withWelding & exacting internal clearances.OverhaulSystem Converter Why 45º? CW3 Converter Welder ATI’s CW3 Gravity pulls the d Overhaul U.S. Patent # 5,000,366 Welding an 45° weld into the pump use in over and cover seam for System is in CW3 Rotational Coupler s and in nearly 100% leak-free 23 countrie production. U.S. Patent # 5,082,299 ughout the shops thro s! United State tion! Why Choose ATI? 149 welde rs in opera Before you invest thousands of dollars and manufacturing engineers on to get into the converter rebuilding a continuous basis and prototyped business, you need to make an many new GM torque converters. intelligent decision on what company ATI manufactures all new race is most qualified to lead you into your converters in-house. From stampings, Easily rotate the machine 180° to weld new venture—one that can supply slottings and blades to assembly and the converter with you with the proper equipment and rolling, each task is performed in- the cover lip over the pump! training to get the job done. house. While this capability is out of Choose a company that not only the realm of most converter shops, supplies the equipment but uses it as well. That’s where ATI Performance Products comes in. ATI uses our own Don’t overpay for your equipment daily to rebuild race torque welding equipment! converters - the same equipment Call ATI and compare! we are selling to you. While some manufacturers tell you that their machinery is on the cutting edge of ATI accomplishes the task of technology and the most effective building brand new torque method to rebuild—only ATI has the converters from start to finish for daily hands-on experience to back up our high performance customers that claim. everyday. At ATI, we have the ATI is an authorized GM vendor technology and our equipment is and has developed a specialized built to exceed the most stringent CW3 welder that fixtures and tig tolerances in the world. tacs 298mm high speed converters What’s this? for the Corvette and supercharged Should your equipment, training When you see a code like this, take a photo with your smartphone and, programs. We’ve worked very closely and procedures be anything less? using free software available at with GM design product planning http://gettag.mobi, you’ll be a click away from more in-depth information from ATI!© 2010 ATI Performance Products, Inc.
  6. 6. While we regret not meeting you in person, we’d like to offer Powertrain attendees and Gears Magazine readers 10% off our torque converter rebuilding equipment! Mention Code PT2010 to receive 10% off your CW3 order. Offer valid through 9-30-2010. Accu-Balance Converter Balancer 220V 1Ø 220V 3Ø Accurately balances converters in under 20 seconds! 95 piece tooling kit included. Quick Test Converter Leak Tester Determine the integrity of a converter in under a minute with this easy-to-use tester. NCERS 141 BALA LY IN CURRENT N! OPERATIO Air pressure only older Already have an stead of ATI Balancer? In e, update buying a new on ATI’s the control with tro Fit Kit! Accu-Balance Re Our generatiothird n accepts a bonder Pass-Through ll pri tooling! or Converter Washer The Converter Washer makes cleaning and degreasing torque Built for maximum performance and safety converters a simple task. in the heat bonding of frictional material to Gas / electric heat / 220V / 440V torque converter clutches. May be factory retooled and designed to perform other Experience the difference! bonding and pressing operations, such as punching, forming, sizing, and laminating. ATI’s converter rebuilding machines are designed specifically to Includes 30 piece steel die tooling kit. increase precision and production in your shop. We know what you work on and we address your needs. No other manufacturer offers you the same level of personal service. At ATI we focus on just ATI’s complete CW3 Converter a few machines. Our systems come complete with many options Welding & Overhaul System available and they will make you money. Talk to an ATI user then • CW3 Converter Welder • Pass Through Converter order your new profit center today. • Accu-Balance Converter Washer Balancer • GM and Ford Welding �������� ������� Poor customer service from your current • Quick Test Leak Tester Fixtures �������� ������� �������������������������� ���������������������� ���� ����� equipment manufacturer? Test us! Call any time • Clutch Piston Bonder • Air Riveter �������� �������� ��������� ������� �������� �������� ����� �� and ask for help as if you’re already our customer! • Cut-Open & Engine Lathes • Tooling and more ��������� All equipment carries a one year parts warranty ��� � ���� ��������� ������ �������� Call or visit us online at www.aticw3.com to get a copy of our latest brochure full of detailed FAMILY OWNED • AMERICAN MADE information on our entire product line! ���� �������� ���� ��������� ���������� ���������� ������� ����������(877)298-5003 www.aticw3.com 6747 Whitestone Road • Gwynn Oak, Maryland 21207 ®

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