Automatic Transmission – 5L40–E – Unit Repair 7E5 – 1

7E5 – 1

Section 7E5

Hydra-Matic 5L40–E Automatic Transmission –

Unit Repair

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

WARNINGS, CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property

damage.

1 Transmission Disassemble...................................................................................................................4

1.1 General Service Information................................................................................................................................. 4

Teflon Sealing Rings .............................................................................................................................................4

Thrust Washer Surfaces........................................................................................................................................ 4

1.2 Transmission Preparation..................................................................................................................................... 5

Torque Converter Assembly Removal................................................................................................................. 5

Holding Fixture Installation................................................................................................................................... 5

Draining Transmission Fluid................................................................................................................................. 6

1.3 Extension Housing ................................................................................................................................................ 7

Remove................................................................................................................................................................... 7

1.4 Pan and Filter Assembly ....................................................................................................................................... 8

Removal.................................................................................................................................................................. 8

1.5 Wiring Harness....................................................................................................................................................... 9

Remove................................................................................................................................................................... 9

1.6 Control Valve Body and Accumulator Assembly.............................................................................................. 10

Remove................................................................................................................................................................. 10

1.7 Output Shaft Speed Sensor ................................................................................................................................ 12

Remove................................................................................................................................................................. 12

1.8 Input Speed Sensor............................................................................................................................................. 13

Remove................................................................................................................................................................. 13

1.9 Torque Converter Housing.................................................................................................................................. 14

Removal................................................................................................................................................................ 14

1.10 Direct and Reverse Clutch - Forward and Coast Clutch................................................................................... 15

Remove................................................................................................................................................................. 15

1.11 Input Sun Gear Shaft........................................................................................................................................... 16

Remove................................................................................................................................................................. 16

1.12 Direct Clutch Hub................................................................................................................................................. 17

Remove................................................................................................................................................................. 17

1.13 Intermediate Clutch Sprag Assembly ................................................................................................................ 18

Remove................................................................................................................................................................. 18

1.14 Overdrive Clutch Housing................................................................................................................................... 19

Remove................................................................................................................................................................. 19

1.15 Low Clutch Sprag ................................................................................................................................................ 20

Removal................................................................................................................................................................ 20

1.16 Centre Support..................................................................................................................................................... 21

Remove................................................................................................................................................................. 21

1.17 Input and Reaction Carrier.................................................................................................................................. 22

Remove................................................................................................................................................................. 22

1.18 Output Shaft......................................................................................................................................................... 23

Remove................................................................................................................................................................. 23

1.19 Park System Components .................................................................................................................................. 24

Remove................................................................................................................................................................. 24

1.20 Transmission Case Assembly............................................................................................................................ 26

Inspect .................................................................................................................................................................. 26

Techline

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 2

7E5 – 2

1.21 Transmission Case Components....................................................................................................................... 27

Disassemble......................................................................................................................................................... 27

Reassemble.......................................................................................................................................................... 27

1.22 Park System Components .................................................................................................................................. 28

Reinstall................................................................................................................................................................ 28

1.23 Output Shaft and Rear Internal Ring Gear......................................................................................................... 30

Disassemble......................................................................................................................................................... 30

Reassemble.......................................................................................................................................................... 30

1.24 Input and Reaction Carrier.................................................................................................................................. 32

Disassemble......................................................................................................................................................... 32

Reassemble.......................................................................................................................................................... 32

1.25 Centre Support..................................................................................................................................................... 35

Disassemble......................................................................................................................................................... 35

Reassemble.......................................................................................................................................................... 38

Alternative Reassembly Method....................................................................................................................... 42

1.26 Low Clutch Sprag ................................................................................................................................................ 43

Reassemble.......................................................................................................................................................... 43

1.27 Overdrive and Intermediate Clutch .................................................................................................................... 44

Disassemble......................................................................................................................................................... 44

Reassemble.......................................................................................................................................................... 46

1.28 Intermediate Clutch Sprag .................................................................................................................................. 53

Inspect .................................................................................................................................................................. 53

Reassemble.......................................................................................................................................................... 54

1.29 Direct Clutch Hub................................................................................................................................................. 55

Reassemble.......................................................................................................................................................... 55

1.30 Input Sun Gear Shaft........................................................................................................................................... 56

Disassemble......................................................................................................................................................... 56

Reassemble.......................................................................................................................................................... 57

1.31 Forward and Coast Clutch .................................................................................................................................. 59

Disassemble......................................................................................................................................................... 59

Reassemble.......................................................................................................................................................... 60

1.32 Direct and Reverse Clutch .................................................................................................................................. 65

Disassemble......................................................................................................................................................... 65

Reassemble.......................................................................................................................................................... 67

1.33 Direct and Reverse Clutch - Forward and Coast Clutch................................................................................... 70

Reinstall................................................................................................................................................................ 70

Alternative Reassembly Method....................................................................................................................... 70

1.34 Fluid Pump ........................................................................................................................................................... 72

Remove................................................................................................................................................................. 72

Disassemble......................................................................................................................................................... 74

1.35 Torque Converter Seal ........................................................................................................................................ 76

Remove................................................................................................................................................................. 76

1.36 Fluid Pump ........................................................................................................................................................... 77

Reassemble.......................................................................................................................................................... 77

1.37 Torque Converter Housing.................................................................................................................................. 83

Reinstall................................................................................................................................................................ 83

1.38 Torque Converter Seal ........................................................................................................................................ 85

Reinstall................................................................................................................................................................ 85

1.39 Control Valve Body and Accumulator Assembly.............................................................................................. 86

Disassemble......................................................................................................................................................... 86

Rear Control Valve Body Inspection.................................................................................................................. 92

Rear Control Valve Body Disassemble.............................................................................................................. 92

Rear Control Valve Body Assemble................................................................................................................... 95

Front Control Valve Body Inspection................................................................................................................. 97

Front Control Valve Body Disassemble............................................................................................................. 98

Front Control Valve Body Assemble.................................................................................................................. 99

Control Valve Body and Accumulator Assembly............................................................................................ 101

Assemble ....................................................................................................................................................... 101

1.40 Input Speed Sensor Installation ....................................................................................................................... 106

1.41 Output Shaft Speed Sensor Installation .......................................................................................................... 107

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 3

7E5 – 3

1.42 Control Valve Body and Accumulator Assembly............................................................................................ 108

Reinstall.............................................................................................................................................................. 108

1.43 Wiring Harness................................................................................................................................................... 110

Reinstall.............................................................................................................................................................. 110

1.44 Pan and Filter Assembly................................................................................................................................... 111

Reinstall.............................................................................................................................................................. 111

1.45 Extension Housing ............................................................................................................................................ 112

Reinstall.............................................................................................................................................................. 112

1.46 Propeller Shaft Flange....................................................................................................................................... 115

Reassemble........................................................................................................................................................ 115

1.47 Holding Fixture Removal................................................................................................................................... 116

1.48 Torque Converter Assembly............................................................................................................................. 117

Reinstall.............................................................................................................................................................. 117

2 Transmission Reference Diagrams..................................................................................................118

3 Specifications.....................................................................................................................................138

4 Torque Wrench Specifications..........................................................................................................143

5 Special Tools ......................................................................................................................................144

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 4

7E5 – 4

1 Transmission Disassemble

1.1 General Service Information

The use of air powered tools to disassemble or reassemble this transmission is not recommended. Apart from the fact

that thread stripping is most likely when incorrect torque values are applied to fasteners, component parts can be

distorted to the point where malfunctions will occur.

Teflon Sealing Rings

If any sealing rings are found to be damaged, cut or do not rotate freely in their groove, check that the ring groov e has no

trapped debris, is not burred or damaged in such a way that early failure of a replaceme nt ring will occur.

Thrust Washer Surfaces

On inspection, thrust washer bearing surfaces may appear to be polished at points of contact. This is a normal condition

and should not be considered as damage, requiring replacement.

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 5

7E5 – 5

1.2 Transmission Preparation

Machined surfaces on alloy castings have

extremely sharp edges that can easily cause

injury and blood loss, through severe cuts.

Take extreme care when working under these

conditions.

Torque Converter Assembly Removal

Take care when removing the torque

converter as it is a heavy assembly

(approximately 12 kilograms) and personal

injury may result if lifted incorrectly.

1 Remove the torque converter assembl y (1) by sliding

clear of input turbine shaft. Drain stored converter fluid

into a suitable container.

Figure 7E5 – 1

Holding Fixture Installation

1 Plug all transmission ope nings and thoroughly clean

the exterior of the transmission.

2 Install the transmission holding fixture (2) J 8763-02

(or E1363) as shown onto the transmission assembly.

Take care when installing the transmission to

the tool base. Use suitable lifting equipment

as the transmission assembly without the

torque converter is still a heavy assembly

(approximately 70 kilograms) and personal

injury may result if lifted incorrectly.

Also, be mindful that the weight of the

transmission, could tip the workbench over.

3 Install the transmission assembl y and holding fixture

into the tool base and use the pin (1) to lock the

holding fixture i n place. Figure 7E5 – 2

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 6

7E5 – 6

4 Using a fine bladed screwdriver, lever out and remove

the input turbine shaft seal (430).

NOTE

If the O-ring seal is not removed at this time,

then removal of the torque co nverter housing will

not be possible.

Figure 7E5 – 3

Draining Transmission Fluid

1 Using a T-45 Torx bit and suitable equipment, remove

the fluid pan drain plug (63) a nd seal (64), and allow

the transmission fluid to drain in to a suitable sized

container (approximatel y 6 litr es).

Figure 7E5 – 4

2 Put transmission in Park.

3 Remove the propeller shaft flange n ut (34), u s ing a 30

mm deep socket and suitable equ ipment.

4 Remove the dished washer (33) from the transmission

output shaft.

5 Remove the propeller shaft flange (3 1) and O-ring seal

(32) from the transmission output shaft. Using a small

screwdriver blade, remove the O-ring seal (3 2) and

discard.

6 Remove holding fixture tool base pin and slowly rotate

the transmission and holding fixture to a vertic al

position, with the torque converter housin g facing up.

Re–insert tool base pin with transmission in this

position and allow any excess fluid to drain into the

suitable container.

Figure 7E5 – 5

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 7

7E5 – 7

1.3 Extension Housing

Remove

1 Rotate the transmission through 180° to a vertical

position with the extension housing facing up.

2 Using seal remover E308 (or commercial equivalent)

and suitable socket equipment, remove the propeller

shaft flange oil seal (29).

3 Using suitable snap ring pliers remove the output shaft

assembly retainer (30) (refer Figure 7E5-5).

4 Remove the extension housin g bolts (35).

5 Remove the extension housin g (27).

6 Remove the extension housing gasket (25).

Figure 7E5 – 6

7 If not retained in the extension housing on removal,

remove the input and reaction carrier thrust bearing

(23) and selective washer (22), from the output shaft

assembly.

NOTE

If the thrust bearing and washer are not removed

at this time, they will probably fall off when the

transmission is rotated for other procedures.

Figure 7E5 – 7

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 8

7E5 – 8

1.4 Pan and Filter Assembly

Removal

1 Remove holding fixture tool base pin and slowly rotate

the transmission and holding fixture so that the fluid

pan (62) is facing up.

Re–insert tool base pin with transmission in this

position.

2 Remove the 10 mm hexagon headed fluid pan bolts

(65), the fluid pan (62) and the gasket (60).

Figure 7E5 – 8

3 Remove the fluid filter (59) from the case (24).

NOTE

Fluid seals (57) will probably remain in the

transmission case (24) after fluid filter (59) has

been removed.

Figure 7E5 – 9

4 Assemble universal seal remover tool J 23129 and

slide hammer tool J 6125-1B together to remove the

fluid filter seals (57) from the case (24).

Figure 7E5 – 10

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 9

7E5 – 9

1.5 Wiring Harness

Remove

1 Using a small scre wdriver to lift the transmission

connector locking tangs, remove the wiring harness

connectors from the following components:

• Pressure Control Solenoid (3 57)

• TCC PWM Solenoid (352)

• 1–2 Shift Solenoid (368)

• 2–3 Shift Solenoid (369)

• 4–5 Shift Solenoid (376)

• Manual Shift Shaft Switch (602)

• Input Speed Sensor (44)

• Output Speed Sensor (42)

Figure 7E5 – 11

2 Using a flat bladed screwdriver, remove the connector

retainer (54) from the transmission case (24).

Figure 7E5 – 12

3 Remove the wiring harness (55) from the transmission

case (24).

Figure 7E5 – 13

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 10

7E5 – 10

1.6 Control Valve Body and Accumulator

Assembly

Remove

1 Remove the E8 Torx headed control valve body bolts

(49, 51).

NOTE

Only remove the bolts (49, 51) nominated in

Figure 7E5-13. Do not remov e the t wo remaining

TX-30 Torx screws at this stage.

Figure 7E5 – 14

2 Remove the 10 mm hexagon headed control valve

body bolts (53).

3 Remove the manual shaft detent lever sprin g

assembly (52).

4 Remove the control valve body and accumulator

assembly (47) from the transmission case (24).

Figure 7E5 – 15

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 11

7E5 – 11

5 Remove the centre support fluid pass ag e sle eve (38)

and the overdrive clutch fluid passage sleeve (39)

from the transmission case (24).

Figure 7E5 – 16

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 12

7E5 – 12

1.7 Output Shaft Speed Sensor

Remove

1 Remove the 10 mm headed output speed sensor

screw (43).

2 Remove the output speed sensor (42).

Figure 7E5 – 17

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 13

7E5 – 13

1.8 Input Speed Sensor

Remove

1 Remove the 10 mm hexagon headed input speed

sensor bolt (45).

2 Remove the input speed sensor (44) from the case

(24).

Figure 7E5 – 18

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 14

7E5 – 14

1.9 Torque Converter Housing

Removal

1 Rotate the transmission assembly 90° so the torque

converter housing is facing up . Remove the torque

converter housing to transmission case bolts (2) from

the torque converter housing (3).

2 Remove the torque converter housing assembly (3)

from the transmission case (24).

NOTE

The transmission fluid pump is attached to the

torque converter housing, making the assembly

heavier than expected.

3 Remove the torque converter housing fluid seal

assembly (4).

4 Remove the fluid pump cover gasket (46).

Figure 7E5 – 19

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 15

7E5 – 15

1.10 Direct and Reverse Clutch - Forward and

Coast Clutch

Remove

1 Remove the forward and coast clutch assembly (7)

and the direct and reverse clutch assembly (6) from

the case (24).

NOTE

Do not damage the input shaft fluid seals when

removing or installing the direct and reverse

coast clutch assembly.

2 Lift the direct and reverse clutch assembly (6) off of

the forward and coast clutch assembly (7).

Figure 7E5 – 20

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 16

7E5 – 16

1.11 Input Sun Gear Shaft

Remove

1 Remove the input sun gear shaft (8) from the case

(24).

Figure 7E5 – 21

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 17

7E5 – 17

1.12 Direct Clutch Hub

Remove

1 Remove the direct clutch hub assembly (10) from the

case (24).

Figure 7E5 – 22

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 18

7E5 – 18

1.13 Intermediate Clutch Sprag Assembly

Remove

1 Remove the intermediate clutch sprag assembly (12)

from the case (24).

Figure 7E5 – 23

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 19

7E5 – 19

1.14 Overdrive Clutch Housing

Remove

Use care when removing or installing the

snap ring. Be sure the J 45126 snap ring

pliers are installed properly onto the retainer

ring or bodily injury may occur.

1 Using suitable snap ring pliers such as J 45126 or

equivalent, remove overdrive clutch housing to

transmission case retainer ring (14).

Figure 7E5 – 24

2 Lift out the overdrive clutch housing (15) from the

transmission case (24).

Figure 7E5 – 25

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 20

7E5 – 20

1.15 Low Clutch Sprag

Removal

1 Remove the low clutch sprag assembly (16) from the

transmission case (24).

2 Remove the low clutch roller thrust bearing (17).

Figure 7E5 – 26

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 21

7E5 – 21

1.16 Centre Support

Remove

1 Using centre support removal tool J 45127, engage

and lift out centre support (18) from the transmission

case (24).

Figure 7E5 – 27

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 22

7E5 – 22

1.17 Input and Reaction Carrier

Remove

1 Remove the input and reaction carrier (19) from the

transmission case (24).

2 Remove the input and reaction carrier thrust bearing

(20) from the case (24).

Figure 7E5 – 28

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 23

7E5 – 23

1.18 Output Shaft

Remove

1 Remove the output shaft assembly (21) from the

transmission case (24).

NOTE

The input and r eaction carrier thrust bearin g (23)

and selective washer (22), have already been

removed, refer to 1.3 Extension Housing, in this

Section.

Figure 7E5 – 29

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 24

7E5 – 24

1.19 Park System Components

Remove

1 Rotate the transmission 90 degrees, so the underside

of the transmission case is facing up ward.

2 Using a suitable sized pin punch and hammer,

carefully knock out the manual shaft detent le ver pin

(601) from the manual shaft (606).

Figure 7E5 – 30

3 Remove the manual shift shaft (606) from the

transmission case (24).

4 Remove the manual shaft detent lever (600), the

manual shaft shift switch assembly (602) and park

pawl actuator assembly (613) from the transmission

case (24).

5 Disconnect the park pawl actuator (613) from the

manual shaft detent lever (600).

Figure 7E5 – 31

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 25

7E5 – 25

6 Using a small scre wdriver, prise the manu al shaft shift

seal (605) from the transmission case (24).

Figure 7E5 – 32

7 Release the park pawl spring t ension, then remove the

spring (611) from the park pawl shaft (610).

8 Remove the park pawl shaft (610) and the park pawl

(612) from the transmission case (24).

Figure 7E5 – 33

9 Remove the park pawl actuator bracket, internal T45

Torx headed bolts (609) from the transmissi on case

(24).

10 Remove the park pawl actuator brackets (607, 608)

from the transmission case (24).

Figure 7E5 – 34

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 26

7E5 – 26

1.20 Transmission Case Assembly

Inspect

1 Inspect the components that are still on the

transmission case for the following conditions:

• Loose, cross-threaded, or damage d threads on

the transmission oil cooler fittings.

• A loose, missing, or damaged transmission

name plate.

Figure 7E5 – 35

2 Inspect the transmission case for the following

conditions:

• Gasket sealing surfaces that are damaged or

have porosity.

• Bolt and screw holes that are stripped or

damaged – repair with thread insert.

• Damaged or porous case and fluid passages.

• Damaged snap ring grooves or housing splines.

• A loose, cross threaded, or damaged pressure

test plug and fluid level hole plug.

Figure 7E5 – 36

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 27

7E5 – 27

1.21 Transmission Case Components

Disassemble

1 Using a 5 mm Allen key socket and suitable

equipment, remove the pressure test plug (40) and O-

ring seal (66).

2 Use a T45 Torx bit and suit able equipment to remove

the level hole plug (36) and O-ring (3 7) from the

transmission case (24).

Figure 7E5 – 37

Reassemble

NOTE

Refer to 4.30 Fasteners in Section 00 Warnings,

Cautions and Notes of this Service Information.

NOTE

If the pressure test plug (40), O-ring (66), level

hole plug (36) and O-rin g (37) are not damaged,

they may be reused.

1 Inspect the pressure test hole plug (40) and O-ring

(66) for damage.

2 Install the pressure test plug (40) and O-ring (66), then

tighten the plug to the correct torque specification.

Transmission pressure test plug

to case torque specification..................................11 N.m

3 Inspect the level hole plug (36) and O-ring (37) for

damage. Figure 7E5 – 38

4 Reinstall the transmission flu id level hole plug O-ring (37) and the transmission level hole plug (36), then tighten the

plug to the correct torque specification.

Transmission level hole plug

to case torque specification..................................11 N.m

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 28

7E5 – 28

1.22 Park System Components

Reinstall

1 Inspect the park system components for the following:

• Worn park pawl actuator brackets (607, 608).

• A damaged or bent park pa wl actuator assembl y

(613).

• A damaged manual shaft detent lever (600).

• A damaged manual shaft shift switch assembly

(602).

• A worn or stripped manual shaft (606).

• A worn or damaged park pawl shaft (610), park

pawl spring (611), and park pawl (612).

Figure 7E5 – 39

2 Install the park pawl actuator brackets (607, 608) onto

the case (24).

NOTE

Refer to 4.30 Fasteners in Section 00 Warnings,

Cautions and Notes of this Service Information.

3 Reinstall the bracket bolts (609) and tighten to the

correct torque specification.

Park pawl actuator bracket to transmission

case bolt torque specification...............................22 N.m

Figure 7E5 – 40

4 Install the park pawl (612), the park pawl shaft (610)

and the park pawl spring (611) into the case (24).

Figure 7E5 – 41

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 29

7E5 – 29

5 Assemble the park pawl actuator (613) to the detent

lever (600).

6 Assemble the shift switch assembly (602) to the detent

lever (600).

7 Reinstall the shift switch assembly (602), detent lever

(600) and park pawl actuator (613) into the

transmission case (24).

8 Reinstall the manual sh aft (606) into the case (24).

Figure 7E5 – 42

9 Align the groove for a NEW manual shaft pin (601)

with the pin hole in the detent lever/shift switch

assembly.

10 Install the NEW manual shaft pin (601) into the manual

shift shaft (606), using a suitable sized pin punch and

hammer.

Figure 7E5 – 43

11 Install a NEW manual shaft seal (605) onto J 44767.

12 Use J 44767 to install the NEW manual shaft seal

(605) into the case (24).

Figure 7E5 – 44

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 30

7E5 – 30

1.23 Output Shaft and Rear Internal Ring Gear

Disassemble

1 Remove the snap ring (563).

2 Remove the output shaft (562) from the rear internal

gear (560).

Figure 7E5 – 45

Reassemble

1 Inspect the output shaft (562) and the rear internal

gear (560) for the following:

• Damaged or worn bushings

• Damaged splines

• Damaged or worn snap ring (563)

• Damaged or worn gear teeth

• Damaged or worn snap ring groove

• Damaged or cross-threaded threads

• Damaged or worn bearings

Figure 7E5 – 46

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 31

7E5 – 31

2 Install the output shaft (562) onto the rear internal gear

(560).

3 Install the snap ring (563) onto the rear internal rin g

gear (560). Be sure it is seated in the groove.

Figure 7E5 – 47

4 Rotate the transmission 90° so the main ope nin g of

the transmission case is facing upward.

5 Install the output shaft assembly (21) into the case

(24).

Figure 7E5 – 48

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 32

7E5 – 32

1.24 Input and Reaction Carrier

Disassemble

1 Remove the snap ring (540) and discard.

2 Remove the input and reaction bear ing (541).

3 Remove the 2nd clutch roller inner race bearing (542).

4 Remove the 2nd clutch sprag (549).

5 Remove the reaction internal gear flange washer

(551).

Figure 7E5 – 49

Reassemble

1 Inspect the reaction internal gear and the 2nd clutch

sprag for the following:

• Damaged or worn gear teeth

• Damaged or worn splines

2 Inspect the input and reaction carrier for the follo wing:

• Damaged or worn teeth

• Damaged or worn splines

• Worn or nicked bushings

• Worn or damaged bearings

Figure 7E5 – 50

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 33

7E5 – 33

3 Lightly coat the reaction internal gear flan ge washer

(551) with petroleum jelly and install onto the front of

the input and reaction carrier assembly.

Figure 7E5 – 51

4 While holding the inner member, check that the outer

member of the 2nd clutch sprag free wheels (arrow)

and locks up in the opposite direction.

Figure 7E5 – 52

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 34

7E5 – 34

5 Install the 2nd clutch sprag (549) onto the input and

reaction carrier (553).

6 Install the 2nd clutch roller inner race bearing

assembly (542) onto the input and reaction carrier

(553).

7 Install the input and reaction bearing assembly (541)

onto the input and reaction carrier (553).

8 Install the NEW input and reaction carrier outer ring

(540) onto the input and reaction carrier (553 ).

Figure 7E5 – 53

9 Install the input and reaction c arrier thrust be aring (20)

into the front of the output shaft and rear internal ri ng

gear assembly (21).

10 Install the input and reaction c arrier (19) into the case

(24), engaging the mating gear teeth.

Figure 7E5 – 54

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 35

7E5 – 35

1.25 Centre Support

Disassemble

1 Using a flat bladed screwdriver, remove the snap ring

(510) from the centre support.

2 Remove the low and reverse backing plate (511).

3 Remove the clutch plates (512, 513), five inner spl ined

plates and five outer splined pl ates (all models).

NOTE

Each clutch plate has a composition lining on

one side while the other is plai n steel.

4 Remove the low and reverse, waved apply plate (514).

Figure 7E5 – 55

5 Using Tool J 23327, compres s the low and reverse

clutch spring (516).

6 Using suitable snap ring pliers, remove the low

reverse clutch spring retainer ring (515) from the

centre support retaining groove.

7 Loosen and remove T ool J 23327 from the centre

support (518).

8 Remove the low and reverse clutch spri ng retainer ring

(515) and clutch spring (516) from the centre supp ort

(518).

Figure 7E5 – 56

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 36

7E5 – 36

Wear eye protection to prevent potential

injury.

9 Remove the low and reverse piston (517) from the

centre support (518).

NOTE

It may be necessary to apply air pressure to the

centre support port as shown, to assist in piston

removal.

Figure 7E5 – 57

10 Turn the centre support assembly over and using a

fine bladed screwdriver, remove the 2nd coast clutch

plate retainer ring (535) from the centre support (518).

11 Remove the 2nd coast clutch backing plate (534) from

the centre support (518).

12 Remove the clutch plates (532, 533), three (two for

5HEG) inner splined plates and three (two for 5HEG)

outer splined plates.

NOTE

Each clutch plate has a composition lining on

one side while the other is plai n steel.

13 Remove the 2nd coast clutch spacer (531) from the

centre support (518).

Figure 7E5 – 58

14 Using a flat bladed screwdrive r , remove the 2nd coast

clutch spring retainer (530).

15 Remove the 2nd coast clutch spring (529) from the

centre support (518).

Figure 7E5 – 59

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 37

7E5 – 37

Wear eye protection to prevent potential

injury.

16 Remove the 2nd coast clutch piston (528) fro m the

centre support (518).

NOTE

It may be necessary to apply air pressure to the

centre support port as shown, to assist in the

removal of the piston.

Figure 7E5 – 60

17 Using a flat bladed screwdriver, remove the retainer

ring (527) from the centre support (518).

18 Remove the 2nd clutch backing plate (526) from the

centre support (518).

19 Remove the clutch plates (524, 525), five inner spl ined

plates and five outer splined pl ates (all models) from

the centre support (518).

20 Remove the 2nd clutch apply plate (523) from the

centre support (518).

Figure 7E5 – 61

21 Using Tool J 23327, compres s the 2nd clutch piston

spring (521).

22 Using suitable snap ring pliers, remove the retainer

ring (522) from the centre support (518) retai nin g

groove.

23 Loosen and remove T ool J 23327 from the centre

support (518).

24 Remove the 2nd clutch piston spring (521) fro m the

centre support (518).

Figure 7E5 – 62

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 38

7E5 – 38

25 Remove the 2nd clutch piston (520) from the centre

support (518).

NOTE

It may be necessary to apply air pressure to the

centre support port as shown, to assist in the

piston removal.

Figure 7E5 – 63

Reassemble

1 Inspect the centre support components for the

following:

• Plugged fluid passages

• Worn or damaged splines

• Worn or damaged pistons

• Worn or damaged clutch plates

2 Install 2nd clutch inner seal protector (Tool J 45137)

and piston protector (Tool J 46240), into the centre

support.

3 Lubricate the 2nd clutch piston and protectors with

clean transmission lubric ant. Install the 2nd clutch

piston (520) into the centre support, using J 233 27 to

assist in the installation process.

Remove Tools J 46240 an d J 45137 once 2nd clutch

piston is installed. Figure 7E5 – 64

4 Install the 2nd clutch piston spring (521) into the

centre support (518), and place the 2nd clutch spring

retainer snap ring (522) on top of the piston spring.

5 Using Tool J 23327, compres s the 2nd clutch piston

spring (521).

6 Using suitable snap ring pliers, install a NEW 2nd

clutch spring retainer ring (522) into the centre support

(518) retaining groove.

7 Loosen and remove T ool J 23327 from the centre

support (518).

Figure 7E5 – 65

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 39

7E5 – 39

8 Install the 2nd clutch apply plate (523) into the centre

support (518).

Ensure that the composition side of each

plate faces upwards.

9 Install the 2nd clutch plates. Start by installing the 2n d

clutch plate (524) with external splines.

Alternate with the 2nd clutch plate (525) with internal

splines.

10 Install the 2nd clutch backing plate (526) into the

centre support (518).

11 Install the 2nd clutch backing plate retainer ring (527)

into the centre support (518).

Figure 7E5 – 66

12 Measure the distance between the 2nd clutch backing

plate and the bottom of the gauge bar. Measure three

times in different locations on the backing pla t e.

Record this as H1.

13 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the 2nd clutch backing

plate and the bottom of the gauge bar. Measure three

times in different locations on the backing pla t e.

Record this as H2.

14 Subtracting H2 from H1 will give the clutch pack travel

dimension.

2nd Clutch Pack

Travel Specification................................ 1.47 – 1.92 mm

Figure 7E5 – 67

15 Install inner piston seal protector (Tool J 46239-2) and

outer piston seal protector (J 46239-1) into the centre

support (518).

16 Coat inner and outer piston seal surfac es with

petroleum jelly (e.g. Vaseli ne™ or equivalent), then

install the 2nd coast piston (528), using installer (Tool

J 48239-3), into the centre support (518).

Figure 7E5 – 68

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 40

7E5 – 40

17 Install the 2nd coast clutch spring (529) into the centre

support (518), with the inner tangs facing downward.

18 Install one end of the coast clutch spring retai ner (530)

into the centre support groove.

19 Using a screwdriver blade as needed, fully install the

retainer by working around its len gth, until the retainer

is fully engaged.

Figure 7E5 – 69

20 Install the 2nd coast clutch spacer (531) into the

centre support (518), checking that the support cut-

outs straddle the coast clutch spring legs.

Ensure that the composition side of each

plate faces upwards.

21 Install the 2nd coast clutch plates, starting with the 2nd

coast clutch plate (532) with external splines. Alternate

with the 2nd coast clutch plate (533) with internal

splines.

22 Install the 2nd coast clutch backing p late (5 34).

23 Install the 2nd coast clutch backing plate retainer ring

(535).

Figure 7E5 – 70

24 Measure the distance between the 2nd coast clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

25 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the 2nd coast clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

26 Subtracting H2 from H1 will give the clutch pack travel

dimension.

2nd Coast Clutch Pack

Travel Specification................................ 0.94 – 1.39 mm

Figure 7E5 – 71

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 41

7E5 – 41

27 Using Tool J 45140 inner seal protector, and Tool J

45136 outer seal protector, install the lo w and reverse

clutch piston (517) into the centre support (518), using

J 44764 to assist.

Figure 7E5 – 72

28 Assemble low and reverse clutch spring (51 6) and a

NEW retainer ring (515) onto the low and reverse

clutch piston.

29 Using Tool J 23327, spring compressor, compress the

low and reverse clutch piston spring (516).

30 Using suitable circlip pliers, install the low and reverse

clutch spring retainer circlip (515) into the centre

support (518) retaining groove.

Loosen and remove T ool J 23327 once circlip (515) is

installed.

Figure 7E5 – 73

31 Install the low and reverse apply pl ate (514) into the

centre support (518).

Ensure that the composition side of each

plate faces upwards.

32 Install the low and reverse clutch plates. Start with the

low and reverse clutch plate (513) with external

splines. Alternate with the low and reverse clutch plate

(512) with internal splines.

NOTE

The external splined plates (513) with the

missing spline, aligns with the large centre

support lug.

33 Install the low and reverse clutch backing p late (511)

and the retainer ring (510) into the centre support

(518). Figure 7E5 – 74

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 42

7E5 – 42

34 Measure the distance between the low and reverse

clutch backing plate and the bottom of the ga uge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

35 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the low and reverse

clutch backing plate and the bottom of the ga uge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

36 Subtracting H2 from H1 will give the clutch pack travel

dimension.

Low and Reverse Clutch Pack

Travel Specification................................ 1.72 – 2.17 mm

Figure 7E5 – 75

37 Using Tool J 45127, install the centre support

assembly (18) into the transmission case (24),

ensuring that the 2nd clutch and 2n d coast clutch

plates fully engage over the mating splines on the

second clutch sprag assembly (545 and 54 9).

Figure 7E5 – 76

Alternative Reassembly Method

Rather than install the individual transmission components described to this point, the following procedure may be more

convenient.

1 Assemble the centre support assembly (18) to the

planetary carrier and 2nd clutch sprag assemblies (19)

and the rear internal gear output shaft (21).

2 With the transmission case in a horizontal position,

install the pre-assembled compon ents into the case.

NOTE

If all clutch plates are correctly engaged, the flui d

passage access holes in the centre support (A),

will be aligned with those in the transmission

case.

Figure 7E5 – 77

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 43

7E5 – 43

1.26 Low Clutch Sprag

Reassemble

1 Inspect the low clutch sprag for the follo wing:

• Worn or damaged splines

• Scoring on the inside diameter of the races

• Wear or cracks

2 Check that the low clutch sprag rotation freewheels

and locks up in the correct direction.

Figure 7E5 – 78

3 Install the low clutch roller thrust bearing (17 ).

4 Install the low clutch sprag (16) into the transmission

case (24), ensure that the splines on the inner race

(505) engage fully with the low and reverse clutch

plates (512).

Figure 7E5 – 79

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 44

7E5 – 44

1.27 Overdrive and Intermediate Clutch

Disassemble

1 Using a flat bladed screwdriver, remove the overdrive

clutch retainer (480) from the overdrive clutch housing

(493).

2 Remove the overdrive clutch backin g plate (481) from

the overdrive clutch housing (493).

3 Remove the overdrive clutch plates (48 2, 483 ), three

inner splined plates and three outer splined plates (all

models).

4 Remove the overdrive clutch spacer (484) from the

overdrive clutch housin g (493).

Figure 7E5 – 80

5 Using a bladed screwdriver, r ele ase one end of the

clutch piston spring retainer ring (485), then gradually

release the ring remainder until free from the retaining

groove in the overdrive clutch housing (493).

6 Remove the retainer ring (485 ) and the overdrive

clutch spring (486) from the overdrive clutch h ousing

(493).

Figure 7E5 – 81

Wear eye protection to prevent potential

injury.

7 Remove the overdrive clutch piston (48 7) from the

overdrive clutch housin g (493).

NOTE

It may be necessary to apply air pressure to the

overdrive clutch housi ng port as sho wn, to assist

in piston removal.

Figure 7E5 – 82

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 45

7E5 – 45

8 Using a fine bladed screwdriver, remove the

intermediate clutch backing pl ate retainer ring (488)

from the overdrive clutch housing (493).

9 Remove the intermediate clutch backing plate (489)

from the overdrive clutch housing (493).

10 Remove the intermediate clutc h plates (4 90, 491), four

(three for 5HEG) inner splined plates and four (three

for 5HEG) outer splined plates from the overd r ive

clutch housing (493).

11 Remove the intermediate clutch apply plate (492) from

the overdrive clutch housing (493).

Figure 7E5 – 83

12 Assemble plate, Tool J 2142 0-02 against the

intermediate clutch cover (496) and Tools J 447 64 and

J 23327 to the overdrive housing (49 3) and tighten

wing nut to draw in the intermediate clutch housing

(496).

13 Using a flat bladed screwdriver, remove the

intermediate clutch housing retain er ring (497) from

the overdrive clutch housing (493).

Figure 7E5 – 84

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 46

7E5 – 46

14 Loosen and remove Tools J 44764 and J 23327 from

the overdrive clutch housing (493).

15 Remove the intermediate clutch housing (496), and

the intermediate clutch spring (494) from the overdrive

clutch housing (493).

Figure 7E5 – 85

16 Remove the intermediate clutc h piston (495) from the

overdrive clutch housin g (496).

Figure 7E5 – 86

Reassemble

1 Inspect the housing for the following:

• Plugged feed passages

• Worn or damaged splines

• Damaged or worn springs

• Damaged or worn pistons

• Worn or damaged clutch plates

Figure 7E5 – 87

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 47

7E5 – 47

2 After lubricating the inner and outer sealing lips of the

intermediate piston (495) with clean transmission fluid,

install piston (495) into the intermedi ate clutch housing

(496).

Figure 7E5 – 88

3 Install the intermediate clutch spring (494) into the

overdrive clutch housin g (493).

4 Install the intermediate housing (496) into the

overdrive clutch housin g (493).

Figure 7E5 – 89

Align the short tang on the intermediate

housing (496) with the semi-circular cut-out

(A) in the overdrive clutch housing (493).

Figure 7E5 – 90

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 48

7E5 – 48

5 Assemble plate, Tool J 2142 0-02 against the

intermediate clutch cover and Tools J 4476 4 and

J 23327 to the overdrive housing (49 3) and tighten the

wing nut to draw in the intermediate clutch housing

(496).

6 Install the intermediate clutch housing retainer ring

(497) to the retaining groove in the overdrive housing

(493).

7 Loosen and remove all tools.

Figure 7E5 – 91

8 Install the intermediate clutch, waved apply plate

(492).

Ensure that the composition side of each

plate faces upwards.

9 Install the intermediate clutch plates. Starting with the

intermediate clutch plates (491) with external splines.

Alternating with the intermediate clutch pl ates (490)

internal splines.

10 Install the backing plate (489) wit h the recessed edge

facing outward.

11 Install the intermediate backing plate retainer ring

(488) into the overdrive housing (493) retaining

groove. Figure 7E5 – 92

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 49

7E5 – 49

12 Measure the distance between the intermediate clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

13 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the intermediate clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

14 Subtracting H2 from H1 will give the clutch pack travel

dimension.

Intermediate Clutch Pack

Travel Specification................................ 1.13 – 1.58 mm

Figure 7E5 – 93

15 Assemble Tools J 45135 and J 44764 to the overdrive

clutch housing. Coat the piston and to ols using the

correct transmission lubricant and install th e overdrive

piston (487).

Remove tools once piston in correctly install ed.

Figure 7E5 – 94

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 50

7E5 – 50

16 Install the overdrive piston spr ing (4 86) into the

overdrive clutch housing, with the inner tangs facing

downward.

17 Install one end of the coast clutch spring retai ner into

the centre support groove then, using a screwdriver

blade as needed, fully install the retainer by working

around its length, until the retainer is fully engaged.

Figure 7E5 – 95

18 Install the overdrive clutch spacer (484), ensuring that

the spacer cut-outs straddle the overdrive clutch piston

spring blades.

Ensure that the composition side of each

plate faces upwards.

19 Install the overdrive clutch plat es. Starting with the

overdrive clutch plates (483) with e xternal splines.

Alternate with the overdrive clutch plates (48 2) with

internal splines.

20 Install the overdrive backing plate (481).

21 Install the overdrive clutch retainer ring (480).

Figure 7E5 – 96

22 Measure the distance between the overdrive clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

23 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the overdrive clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

24 Subtracting H2 from H1 will give the clutch pack travel

dimension.

Overdrive Clutch Pack

Travel Specification................................ 1.60 – 2.05 mm

Figure 7E5 – 97

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 51

7E5 – 51

25 With the transmission case rotated to a vertical

position as shown, install the overdrive clutch housing

(15) into the transmission case (24).

Check that the mating splines on the intermediate

clutch plates (490) engage fully over the low and

reverse sprag assembly outer race (505).

Figure 7E5 – 98

26 Measure the distance from the bottom of the gaug e

bar to the top of the overdrive and intermedia t e clutch.

Record this as M1.

27 Measure the distance from the bottom of the gaug e

bar to the bottom of the intermediate and overdrive

retainer ring groove in the case. Record this as M2.

28 Subtract M2 from M1. This will be Dimension 'M' .

Figure 7E5 – 99

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 52

7E5 – 52

29 Measure the intermediate and overdrive clutch

housing retaini ng ring (14).

Refer to the following Intermediate and Overdrive

Clutch Housing Retaining Rin g Specifications for the

correct size retainer ring to use.

Intermediate and Overdrive Clutch Housing

Retainer Ring Specification

Dimension 'M' Retainer Ring Thickn ess

(mm)

0.75 mm–0.85 mm 3.90–4.00

0.85 mm–0.95 mm 3.80–3.90

0.95 mm–1.05 mm 3.70–3.80

1.05 mm–1.15 mm 3.60-3.70

1.15 mm–1.25 mm 3.50–3.60

1.25 mm–1.35 mm 3.40–3.50

Figure 7E5 – 100

Use care when removing or installing the

circlip (14). Be sure the circlip pliers are

installed properly onto the circlip 'eyes' or

bodily injury may occur.

NOTE

If any of the following components are replaced,

then an end play measurement must be taken

(refer to 1.45 Extension Housing, in this

Section.):

15 Overdrive Clutch Housing

16 Low Clutch Sprag Assembly

17 Low Clutch Roller Thrust Bearing

18 Centre Support

19 Input and Reaction Carrier Assembly

Figure 7E5 – 101

It is critical that the ends of the circlip are

aligned with the opening in the transmission

case. Otherwise the control valve body

cannot be installed.

30 Using suitable circlip pliers such as Tool J 45126 or equivalent, install the intermediate and overdrive clutch

housing retaining circlip (14) into the transmission case (24). Ensure that the ends of the circlip are positio ned as

shown.

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 53

7E5 – 53

1.28 Intermediate Clutch Sprag

Inspect

1 Inspect the intermediate sprag clutch for the following

conditions:

• Scoring.

• Wear or cracks.

Figure 7E5 – 102

2 Check that the intermediate sprag clutch rotation

freewheels and locks up in the correct direction.

Figure 7E5 – 103

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 54

7E5 – 54

Reassemble

1 Apply some petroleum jelly to the input and reaction

carrier inner shaft thrust washer (11) and install into

the intermediate sprag clutch assembly (12).

Figure 7E5 – 104

2 Install the intermediate sprag clutch assem bly (12) into

the transmission case (24), ensuring that the mating

splines on the intermediate sprag clutch (1 2) engage

fully over both the overdrive clutch plates (482) and

the intermediate clutch plates (490).

Figure 7E5 – 105

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 55

7E5 – 55

1.29 Direct Clutch Hub

Reassemble

1 Inspect the drum for the following:

• Worn or damaged splines

• Worn or damaged bushings

• Wear, cracks and scoring on the shaft

2 Install the direct clutch drum hub thrust washer (9) into

the drum (10).

Figure 7E5 – 106

3 Install the direct clutch drum (10) into the transmission

case (24).

Figure 7E5 – 107

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 56

7E5 – 56

1.30 Input Sun Gear Shaft

Disassemble

1 Remove the forward clutch sprag outer race (459).

2 Remove the forward clutch outer race washer (458).

3 Remove the forward clutch sprag assembly retaining

rings (460).

4 Remove the forward clutch sprag (461).

Figure 7E5 – 108

5 Remove the forward clutch roller inner thrust race

thrust snap ring (455), using suitable snap ring pliers.

6 Remove the inner thrust bearing (456).

Figure 7E5 – 109

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 57

7E5 – 57

Reassemble

1 Inspect the outer race and input shaft for the following:

• Worn or damaged splines

• Scoring inside the diameter of the race

• Wear or cracks

2 Inspect the sprag elements for flat spots.

3 Inspect the cage for distortion or broken ribbon tabs.

4 Inspect the inner bearing for cracks.

Figure 7E5 – 110

5 Install the forward clutch roller inner thrust beari ng

(456).

6 Install a NEW inner race snap ring (455).

Figure 7E5 – 111

7 Install the outer race washer (458) onto the outer race

(459).

8 Install the retaining rings (460) and the forward clutch

sprag (461) onto the outer race (459).

9 Install the sprag assembly (460, 461, 459) onto the

sun gear shaft (457).

Figure 7E5 – 112

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 58

7E5 – 58

10 While holding the forward clutch sprag race with the

left hand, check that the sun gear shaft (457) rotates in

the direction shown and locks in the reverse direction.

Figure 7E5 – 113

11 Install the input sun gear shaft (8) into the

transmission (24).

Figure 7E5 – 114

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 59

7E5 – 59

1.31 Forward and Coast Clutch

Disassemble

1 Using a flat bladed screwdriver, remove the forward

clutch backing plate retainer ring (45 1).

2 Remove the forward clutch backing plate (450).

3 Remove the forward clutch plates (448, 449) .

4 Remove the forward apply p late (447).

Figure 7E5 – 115

5 Remove the coast clutch housing (4 46).

6 Remove the coast backing plat e (445).

7 Remove the coast clutch plates (443, 444).

8 Remove the coast apply plate (442).

9 Remove the coast clutch spacer plate (441).

Figure 7E5 – 116

10 Position the forward clutch housing assembly (433) on

suitable flat press plates and place in a press.

Using Tool J 43074, clutch spring compressor, press

down on the forward and coast clutch spring (439) just

enough to allow access to the retaining circlip (440).

NOTE

As an alternative to J 43074, using J 23327-1

and adaptor plate J 25018-A is also effective .

11 Using suitable circlip pliers, re move the retaining

circlip (440) from the forward clutch housing retainer

ring groove.

12 Release the press and remove Tool J 43074 (or

J 23327-1 / J 25018-A).

13 Remove the forward clutch housing assembly (433)

from the press and remove the clutch spring (439).

Figure 7E5 – 117

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 60

7E5 – 60

Wear eye protection to prevent potential

injury.

14 Remove the coast clutch piston (438).

15 Remove the forward clutch piston (436).

NOTE

It may be necessary to apply air pressure to the

forward clutch housing assembly port as shown,

to assist in the removal of the pistons.

Figure 7E5 – 118

16 Remove the solid input shaft fluid seal (431) by

carefully cutting the seal ring.

17 Remove the three scarf cut input shaft fluid seals

(432).

Figure 7E5 – 119

Reassemble

1 Inspect the forward clutch housing (433) for the following:

• Plugged feed passages.

• Damaged ball check valve (434).

• Worn or damaged splines.

• Seal ring groove nicks or burrs.

• Cracked or blocked fluid passages in the input shaft.

• Worn or damaged clutch plates.

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 61

7E5 – 61

2 Inspect the NEW input shaft fluid seals (431, 432) for

damage.

3 After lubricating with clean transmission flui d, carefully

install the NEW input shaft fluid seals (432), installing

the one closest to the forward clutch housi ng (433)

first, then work outwards.

Figure 7E5 – 120

4 Slide Tool J 45130-2 over the input shaft. Adjust the

position of Tool J 45130-2 b y twisting the adjusting

screw at the top of the tool so that the bottom end is at

the seal groove furthest from the housin g. Coat J

45130-2 with clean transmission fluid.

5 Guide a NEW seal (431) onto T ool J 45130-2 and

slide the seal into the groove with T ool J 45130-1.

6 Remove Tool J 45130-2.

Figure 7E5 – 121

7 After lubricating the inner surface of Tool J 45130-3

with clean transmission lubricant, size the seals (431,

432) by carefully install the sizing Too J 45130-3 over

them.

8 Leave Tool J 45130-3 in place for at least five minutes.

If possible, leave Tool J 45130-3 in place until you

install the assembly into the transmission case.

Figure 7E5 – 122

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 62

7E5 – 62

9 Inspect the forward piston and the coast clutch piston

for the following:

• Cracks or damage to seal grooves.

• Wear on the piston.

• Worn or damaged clutch plates.

10 Use Tool J 45134 to install the forward clutch piston

(436). Coat Tool J 45134 and the for ward clutch piston

seals with clean transmission fluid. Assembly the

forward clutch piston over the tool and push down into

the forward clutch housing.

Remove Tool J 45134.

Figure 7E5 – 123

11 Use Tool J 45132 to install the coast clutch piston

(438). Coat Tool J 45132 and the coast clutch piston

seals with clean transmission fluid. Assembly the

coast clutch piston over the tool and push do wn into

the forward clutch housing.

Remove Tool J 45132.

Figure 7E5 – 124

12 Inspect the forward and coast clutch piston spring for

the following:

• Damaged cage.

• Distorted or missing springs.

13 Install the piston spring (439).

14 Position the forward clutch housing assembly (433) on

suitable flat press plates and place in a press.

Using Tool J 43074 (J , clutch spring com pre ssor,

press down on the forward and coast clutch spring

(439) just enough to allo w access to the retaining

circlip groove. NOTE

As an alternative to J 43074, using J 23327-1

and adaptor plate J 25018-A is also effective .

15 Using suitable circlip pliers, install the retaining circlip

(440) to the forward clutch housing retainer ring

groove.

16 Release the press and remove Tool J 43074 (or

J 23327-1 / J 25018-A).

17 Remove the forward clutch housing from the press.

Figure 7E5 – 125

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 63

7E5 – 63

18 Measure the distance from the top of the forward

clutch housing to the coast clutch piston (438), record

this as dimension C.

19 Measure the distance from the top of the forward

clutch housing to the forward clutch pisto n (4 36),

record this as dimension B.

20 Subtract dimension C from dimension B. This is now

dimension A.

21 Install the coast clutch backing plate (445) into the

coast clutch housing (446).

Figure 7E5 – 126

Ensure that the composition side of each

plate faces upwards.

22 Install the coast clutch plates into the coast clutch

housing (446). Starting with the coast clutch plate

(443) with outer splines. Alternating with the coast

clutch plate (444) with inner splines.

23 Install the coast clutch apply plate into the coast clutch

housing (446).

24 Install the coast clutch spacer plate (441) into the

coast clutch housing (446).

25 Measure the distance from the top of the coast clutch

housing (446) to the top of the coast clutch spacer

plate (441), record this as dimension B.

26 Subtract dimension B from dimension A, this is clutch

pack travel.

Coast Clutch Pack

Travel Specification................................ 1.17 – 1.67 mm

Figure 7E5 – 127

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 64

7E5 – 64

27 Install the coast clutch spacer plate (441).

28 Install the coast clutch waved appl y plate (442).

Ensure that the composition side of each

plate faces upwards.

29 Install the coast clutch plates, starting with the coast

clutch plate (443) with the outer splines, alternating

with the coast clutch plate (444) with inner splines.

30 Install the coast clutch backing plate (445).

31 Install the coast clutch housing (446).

Figure 7E5 – 128

32 Install the forward clutch apply plate (447).

Ensure that the composition side of each

plate faces upwards.

33 Install the forward clutch plates. Starting with the

forward clutch plate (448) with outer splines.

Alternating with the forward clutch plate (449) with

inner splines.

34 Install the forward clutch backing plate (450).

35 Install the forward clutch backing plate retainer ring

(451).

Figure 7E5 – 129

36 Measure the distance between the forward clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

37 Apply air pressure to the specified port. Measure the

distance between the forward clutch backing plate and

the bottom of the gauge bar. Measure three times in

different locations on the backing plate. Record this as

H2.

38 Subtract H2 from H1 this is the clutch pack travel.

Forward Clutch Pack

Travel Specification................................ 1.20 – 1.65 mm

39 At this time you do not install the forward and coast

clutch assembly (7) into the transmission case. Set

aside until told to do so.

Figure 7E5 – 130

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 65

7E5 – 65

1.32 Direct and Reverse Clutch

Disassemble

1 Using a fine bladed screwdriver, remove the reverse

clutch backing plate retainer ring (42 0).

2 Remove the backing plate (419).

3 Remove the clutch plates (418, 417).

4 Remove the apply plate (416).

5 Remove the reverse clutch spacer (415).

Figure 7E5 – 131

6 Remove the direct clutch backing plate reta iner ring

(414).

7 Remove the backing plate (413).

8 Remove the clutch plates (412, 411).

9 Remove the apply plate (410).

Figure 7E5 – 132

10 Using Tools J 38734 and J 45139, compress the direct

and reverse piston spring (407).

11 Using suitable snap ring pliers, remove the direct and

reverse clutch spring retainer ring (409).

12 Loosen and remove J 387 34 and J 45139.

Figure 7E5 – 133

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 66

7E5 – 66

13 Remove the spring retainer (408).

14 Remove the spring (407).

Figure 7E5 – 134

Wear eye protection to prevent potential

injury.

15 To remove the direct clutch piston (406), assembl e the

reverse clutch housing to the fluid pump assembly.

Then apply air pressure to the fluid pump assembly

port as shown, to remove the piston.

Figure 7E5 – 135

16 Remove the reverse clutch piston (404).

17 Remove the reverse clutch piston inner O-ring sea l

(402).

Figure 7E5 – 136

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 67

7E5 – 67

Reassemble

1 Inspect the reverse clutch housing (401) for the

following:

• Plugged feed passages

• Worn or damaged splines

• Seal ring groove nicks or burrs

• Cracked or blocked fluid passages

• Worn or damaged bushing

2 Inspect the reverse clutch piston and the direct clutch

piston for the following:

• Cracks or damage to seal grooves

• Wear on the piston

• Inner seal damage

• Damaged ball check valve (405)

• Worn or damaged clutch plates

3 Install a NEW reverse clutch piston inner O-ring seal

(402).

4 After lubricating with petroleum jelly, install the reverse

clutch piston (404).

Figure 7E5 – 137

5 Install Tool J 45133 onto the direct an d reverse clutch

housing (401).

6 Coat Tool J 45133 and the direct clutch piston (406)

seals with petroleum jelly. Assemble the dir ect clutch

over the tool and push down into the direct and

reverse clutch housing.

Figure 7E5 – 138

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 68

7E5 – 68

7 Install the piston spring (407).

8 Install the piston spring retainer (408).

Place new direct and reverse clutch spri ng retainer

ring (409) on top of piston spring retainer (408).

Figure 7E5 – 139

9 Using Tools J 38734 (1) and J 45139 (2), compress

the direct and reverse piston spring (407).

10 Using suitable snap ring pliers, install the new direct

and reverse clutch spring retainer ring (409).

Figure 7E5 – 140

11 Install the direct clutch apply plate (410).

Ensure that the composition side of each

plate faces upwards.

12 Install the clutch plates (412, 411), starting with the

direct clutch plate (411) with outer splines, alternating

with the direct clutch plate (412) with inner splines.

13 Install the backing plate (413).

14 Install the backing plate retainer (414).

Figure 7E5 – 141

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 69

7E5 – 69

15 Measure the distance between the direct clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

16 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the direct clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

17 Subtract H2 from H1 this is the clutch pack travel.

Direct Clutch Pack

Travel Specification................................ 1.41 – 1.86 mm

Figure 7E5 – 142

18 Install the reverse clutch spacer (415).

19 Install the apply plate (416).

Ensure that the composition side of each

plate faces upwards.

20 Install the clutch plates (417, 418), starting with clutch

plates (417) with outer splines, alternating with clutch

plates (418) with inner splines.

21 Install the reverse clutch backing plate (419).

22 Install the reverse clutch backing plate retainer (420).

Figure 7E5 – 143

23 Measure the distance between the reverse clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H1.

24 Apply air pressure – 450 kPa, to the specified port.

Measure the distance between the reverse clutch

backing plate and the bottom of the gauge bar.

Measure three times in different locations on the

backing plate. Record this as H2.

25 Subtract H2 from H1 this is the clutch pack travel.

Reverse Clutch Pack

Travel Specification................................ 0.98 – 1.43 mm

Figure 7E5 – 144

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 70

7E5 – 70

1.33 Direct and Reverse Clutch - Forward and

Coast Clutch

Reinstall

Do not damage the input shaft fluid seals

when removing or installing the direct and

reverse coast clu t ch assembly.

1 Place the direct and reverse clutch assembly (6) onto

the forward and coast clutch assembly (7).

Figure 7E5 – 145

2 Install the direct and reverse clutch assembly (6) and

the forward and coast clutch assembly (7) into the

case (24).

Figure 7E5 – 146

Alternative Reassembly Method

1 Pre-assemble the input sun gear shaft (457) and sprag clutch (459) assembly to the forward and coast clutch

assembly (7).

Do not damage the input shaft fluid seals

when removing or installing the direct and

reverse coast clu t ch assembly.

2 Install the direct and reverse clutch (6) over the input shaft and engage the direct and reverse clutch plates with the

splines on the forward and coast clutch assembly (7).

3 Install the direct clutch assembl y (10) over the inp ut sun gear shaft (8).

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 71

7E5 – 71

Figure 7E5 – 147

NOTE

This assembling process will be easier, if the

separate assemblies are mounted on the torque

converter housing and fluid pump assembly (3).

Figure 7E5 – 148

4 With the transmission case rotated to the horizontal position (fluid pan side up), remove the pre-assembled

components from the torque converter housing (3) and install them into the transmission case (24).

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 72

7E5 – 72

1.34 Fluid Pump

Remove

1 Remove the fluid pump to torque converter housing

bolts (240, 241).

NOTE

Bolts '240' are T30 Torx bit headed, while bolts

'241' are Torx bit heade d T45.

Figure 7E5 – 149

2 Remove the fluid pump cover (202).

Figure 7E5 – 150

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 73

7E5 – 73

3 Remove the pump vane ring (221).

4 Remove the pump vanes (222).

NOTE

If not replacing pump components, remove

vanes and keep in their original relationships

with the pump rotor (223.

5 Remove the pump rotor (223).

6 Remove the pump rotor guide (224).

7 Remove the pump vane ring (225).

Figure 7E5 – 151

The pump slide spring (219) is under a high

load. Wear eye protection and place a rag

over the spring before and during removal, to

prevent possible injury.

8 Remove the pump slide spring (219).

9 Remove the pump slide (216).

10 Remove the fluid pump slide pin (231).

11 Remove the pump slide ring (220, 242).

12 Remove the fluid pump suppo r t (217) and the fluid

pump slide seal (218).

Figure 7E5 – 152

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 74

7E5 – 74

Disassemble

1 Remove the reverse clutch housing seal rings (200).

Figure 7E5 – 153

2 Remove the line boost valve retainer (20 4).

3 Remove the line boost valve bushing (206) and the

line boost valve (207).

4 Remove the line boost valve bushing seal (205).

5 Remove the line boost valve s prin g (208) and the

pressure regulator valve spring (209).

6 Remove the pressure regulator valve (210).

Figure 7E5 – 154

7 Remove the fluid pump cover screen pin (211).

NOTE

The pin hole has been staked to prevent

accidental pin loss.

8 Remove the pump cover screen (213).

9 Remove the fluid pump cover O-ring seal (212).

Figure 7E5 – 155

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 75

7E5 – 75

10 Remove the pressure relief ball pi n (211).

11 Remove the pressure relief spring (2 38) and the

pressure relief ball (239).

Figure 7E5 – 156

12 Remove the TCC control valve pin (2 04).

13 Remove the TCC control valve sprin g (234) and the

TCC control valve (235).

Figure 7E5 – 157

14 Inspect the input shaft bearing (201) for the following:

• Damaged bearing cage

• Pitted bearings

• Scored bearings

15 If the bearing is damaged, inst all Tool J 45143 onto

the fluid pump.

16 Assemble Tools J 29369-2 on to J 45124 together and

install into the fluid pump and tighten J 29369-2.

17 Tighten J 45124 to remove the input shaft beari ng

(201).

Figure 7E5 – 158

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 76

7E5 – 76

1.35 Torque Converter Seal

Remove

1 Remove the two screws (228), using Torx bit T20 and

suitable equipment.

2 Remove the torque converter seal using Tool J 45000

(as shown), E308 or commercial equivalent.

Figure 7E5 – 159

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 77

7E5 – 77

1.36 Fluid Pump

Reassemble

1 Inspect the bushing (215) for wear – not serviced

separately. If found to be faulty or excessively worn,

replace the fluid pump assembly.

Figure 7E5 – 160

2 Inspect the oil pump parts for the following:

• Worn, scored or gouged pump slide (216).

• Cracks, wear or damage to the rotor (223),

vanes (222), rotor guide (224) or vane guide

rings (221, 225).

• Cuts or damage to the fluid pump slide O-ring

seal (242 and slide seal (not shown).

• Broken or distorted pump slide spring (21 9).

Figure 7E5 – 161

3 Inspect the oil pump housing for the following:

• Porosity.

• Interconnected oil passages.

• Damaged machined surfaces.

Figure 7E5 – 162

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 78

7E5 – 78

4 The bushing (206), valves 207, 210, 235 and 237 for

nicks or burrs.

5 Inspect springs 208, 209, 219, 234 (2 places) and 238,

for wear, distortion or cracks.

Figure 7E5 – 163

6 Install the TCC control valve spring (234), TCC enable

valve (237) and secure with pin (236.

7 Install the TCC control valve (235) and the TCC

control valve spring (234).

8 Install the TCC control valve spring retainer (204).

Figure 7E5 – 164

9 Install the pressure relief valve bal l (239) and spring

(238).

10 Compress the pressure valve spring, then ins t all the

retainer (211).

Figure 7E5 – 165

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 79

7E5 – 79

11 Install the new pump cover O-ring (212) onto a NEW

pump cover screen (213).

12 Install the pump cover screen (213) assembly.

13 Install the pump cover screen pin (211), then lightly

stake the housing to retain.

Figure 7E5 – 166

14 Install the pressure regulator valve (210), the pressure

regulator valve spring (209), a nd the line boost valve

spring (208).

15 Install the line boost valve bushing O-ring (205) onto

the bushing (206).

16 Install the line boost valve (207) into the bushing

(206), then install the sub-assembl y.

17 Apply a load to the bushing, then install the line boost

valve bushing retainer (204).

Figure 7E5 – 167

18 Install the reverse clutch housing fluid seal rings (200).

Figure 7E5 – 168

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 80

7E5 – 80

19 Measure the distance from the bottom of the gaug e

bar to the pump body. Refer to the following Fluid

Pump Specifications Chart.

20 Measure the thickness of pump slide (216).

21 Select the proper size. Refer to the following Fluid

Pump Specifications Chart.

22 Measure the thickness of the pump rotor (223).

23 Select the proper size rotor, refer to the follo wing Fluid

Pump Specifications Chart.

Figure 7E5 – 169

Fluid Pump Specifications Chart

Rotor and slide must be chosen from the

same size classification as the fluid pump

body.

Allowable rotor and slide to fluid pump body end play is as follows:

Rotor and Slide to Fluid Pump Body End Play

Slide to Fluid Pump Body End Pla y – 0.030–0.051 mm

Rotor to Fluid Pump Body End Pla y –0.030 –0.051 mm

The fluid pump assembly has a selectiv e rotor and slide components. These compone nts are chosen based on pump

body dimensions. Fluid pump rotor and slide components ar e available in five size classifications (1, 2, 3, 4, and 5) with

the following tolerances.

Rotor Selection Slide Selection Fluid Pump Body Depth

1 17.948–17.961

mm 1 17.948–17.961

mm 1 17.978–18.012

2 17.961–17.974

mm 2 17.961–17.974

mm 2 17.978–18.025

3 17.974–17.987

mm 3 17.974–17.987

mm 3 18.004–18.038

4 17.987–18.000

mm 4 17.987–18.000

mm 4 18.017–18.051

5 18.000–18.013

mm 5 18.000–18.013

mm 5 18.030–18.064

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 81

7E5 – 81

24 Install the fluid pump support (217), the sli de seal

(218) and the fluid pump slide rings (220), and the fluid

pump slide O-ring seal (242) onto the pump slide

(216).

25 Install the slide pin (231).

26 Install the pump slide (216).

NOTE

The fluid pump side (216) is selective, refer to

Step 20 in this procedure.

Wear eye protection to prevent potential

injury.

27 Using a wide bladed screwdriver (or a section of

hacksaw blade), install the slide spring (219).

Figure 7E5 – 170

28 Install the fluid pump vane ring (225).

29 Install the pump rotor guide (224).

NOTE

The fluid pump rotor guide (224) can only be

installed one way.

30 Install the pump rotor (223).

NOTE

The fluid pump rotor (223) is selective, refer to

Step 20 in this procedure.

31 Install the pump vanes (222).

32 Install the pump vane ring (221).

Figure 7E5 – 171

33 Install the pump cover housing (202) onto the

converter housing (224).

Figure 7E5 – 172

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 82

7E5 – 82

34 Loosely install the fluid pump cover to torque converter

housing bolts (240, 241) but do not tighten at this time.

35 Install Tool J 21368.

Figure 7E5 – 173

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

36 Tighten the fluid pump cover to torque converter

housing bolts (240, 24 1) to the correct torque

specifications.

Transmission fluid pump cov er to torque

converter housing bolts (240)

torque specification..............................................11 N.m

Transmission fluid pump cov er to torque

converter housing bolts (241)

torque specification..............................................22 N.m

37 Remove Tool J 21368.

Figure 7E5 – 174

38 Assemble Tools J 33832 (2) and J 8092 (1). Press the

input shaft bearing assembly (201).

Figure 7E5 – 175

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 83

7E5 – 83

1.37 Torque Converter Housing

Reinstall

1 Inspect the transmission vent pipe for damage or being plugged. If the vent pipe is damaged, the torque converter

housing (227) must be replaced.

2 Measure the distance from the bottom of the gauge

bar to the top of the direct and reverse clutch

assembly (6). Record this as dimension 'X'. Refer to

the following specifications chart to determi ne the

correct size to use.

Reverse Clutch Hou sing Selective Thrust Washer

Specification.

Dimension 'X' Washer Thickness (mm)

50.18 mm–50.36 mm 2.53–2.68

50.36 mm–50.54 mm 2.71–2.86

50.54 mm–50.72 mm 2.89–3.04

50.72 mm–50.90 mm 3.05–3.20

50.90 mm–51.08 mm 3.25–3.40

51.08 mm–51.26 mm 3.43–3.58

51.26 mm–51.44 mm 3.61–3.76

51.44 mm–51.62 mm 3.79–3.94

Figure 7E5 – 176

3 Apply petroleum jell y to a NEW torque converter fluid

O-ring seal (4), and install seal onto the torqu e

converter housing (3).

Figure 7E5 – 177

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 84

7E5 – 84

4 Apply petroleum jell y the reverse clutch housing thrust

washer (5) and install onto the fluid pump (20 2).

Figure 7E5 – 178

5 Install the NEW fluid pump cover gasket (46).

6 Install the torque converter housing (3) o nto the

transmission case (24).

7 Install the torque converter housing b olts (2) and hand

tighten.

Figure 7E5 – 179

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

8 Tighten the torque converter housing bolts in the

correct sequence as shown and to the correct torque

specification.

Torque converter housing to transmission

case bolt torque specification...............................22 N.m

Figure 7E5 – 180

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 85

7E5 – 85

1.38 Torque Converter Seal

Reinstall

1 Assemble Tool J 8092 into Tool J 44766.

Install the seal onto the installation tool

before installing into the case to prevent

damage to the seal.

2 Install the seal (229) onto installer, Tool J 44766.

NOTE

Align the torque converter seal with the bolt

holes

3 Install the NEW seal (229) into the housing (3).

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

4 Install NEW seal screws (228) and tighten to the

correct torque specification.

Torque converter seal to housing screw

torque specification.............................................3.6 N.m

Figure 7E5 – 181

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 86

7E5 – 86

1.39 Control Valve Body and Accumulator

Assembly

Disassemble

Note the position of each accumulator

before removal. The accumulators must

be assembled in the same positions, or

damage may occur.

1 Remove the 2nd clutch accumulator housing bolts

(318).

2 Remove the 2nd clutch accumulator housi ng (333),

piston (inside housing) and spring (329).

Figure 7E5 – 182

3 Remove the intermediate clutc h housing bolts (318).

4 Remove the intermediate clutch accumulator housing

(328), piston (inside housing) and spring (324).

Figure 7E5 – 183

5 Remove the overdrive clutch accumulator housing

bolts (318).

6 Remove the overdrive clutch accumulator housing

(323), piston (inside housing) and spring (319).

Figure 7E5 – 184

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 87

7E5 – 87

7 Remove the direct clutch accumulator housi ng bolts

(318).

8 Remove the direct accumulator housing (317), piston

(inside housing) and spri ng (313).

Figure 7E5 – 185

NOTE

It may be necessary to use air pressure to

remove the piston.

9 Release the piston with air pressure.

Figure 7E5 – 186

10 Remove the 2nd clutch accumulator piston (331) from

the 2nd clutch accumulator housi ng (333).

11 Remove the 2nd clutch accumulator piston rings (332,

330).

Figure 7E5 – 187

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 88

7E5 – 88

NOTE

It may be necessary to use air pressure to

remove the piston.

12 Release the piston with air pressure.

Figure 7E5 – 188

13 Remove the intermediate clutc h accumu lator piston

(326) from the intermediate clutch accumulator

housing (328).

14 Remove the intermediate clutc h accumu lator piston

fluid seal rings (325, 327).

Figure 7E5 – 189

NOTE

It may be necessary to use air pressure to

remove the piston.

15 Release the piston with air pressure.

Figure 7E5 – 190

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 89

7E5 – 89

16 Remove the overdrive clutch accumulator piston (321)

from the overdrive clutch accumulator housing (323).

17 Remove the overdrive clutch accumulator piston fluid

seal ring (320, 322).

Figure 7E5 – 191

NOTE

It may be necessary to use air pressure to

remove the piston.

18 Release the piston with air pressure.

Figure 7E5 – 192

19 Remove the direct accumulator housing piston (315)

from the direct accumulator housing (317).

20 Remove the direct clutch accumulator piston fluid seal

rings (314, 316).

Figure 7E5 – 193

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 90

7E5 – 90

21 Remove the control valve bod y bolts (50, 30 0).

Figure 7E5 – 194

22 Remove the control valve bod y channel plate (301).

23 Remove the channel plate ba ll check spring (302) and

the gasket (303).

Figure 7E5 – 195

24 Remove the control valve bod y channel plate (304).

Figure 7E5 – 196

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 91

7E5 – 91

25 Remove the checkballs (306) and the gasket (305).

NOTE

The checkballs (306) may be inside the bottom

channel plate (304), or may be sitting on gasket

(305).

Figure 7E5 – 197

26 Remove the control valve bod y spacer plate (307).

27 Remove the filters (308, 312).

28 Remove the spacer plate gasket (309).

Figure 7E5 – 198

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 92

7E5 – 92

Rear Control Valve Body Inspection

1 Inspect the rear control valve body (365) for the

following conditions:

• Damaged or porous casting.

• Damaged sealing surfaces.

• Debris in fluid passages.

2 Use a small pick or screwdriver , before disassembly,

to inspect the rear control valve body (365)

components for the following conditions:

• Valves binding or sticking in their bores or

bushings.

• Broken missing or damaged springs.

• Missing or damaged retainers.

• Damaged solenoid valves.

• Debris in valve line ups or solenoid valves.

3 During disassembly, inspect the rear control valve

body (365) for the follo wing conditi ons:

• Worn or damaged valves, valve bores or

bushings.

• Broken, missing or damaged springs.

• Missing or damaged retainers.

• Damaged solenoid valves.

• Debris in valve line ups or solenoid valve.

Figure 7E5 – 199

Rear Control Valve Body Disassemble

1 Remove the 1–2 shift valve retainer (343).

2 Remove the 1–2 shift valve spring (388).

3 Remove the 1–2 shift valve (387).

Figure 7E5 – 200

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 93

7E5 – 93

4 Remove the reverse lock out valve retainer (343).

5 Remove the reverse lock out spring (386).

6 Remove the reverse lock out valve (385).

Figure 7E5 – 201

7 Remove the low pressure cont rol valve bore retainer

(384).

8 Remove the bore plug (381).

9 Remove the low pressure control valve spring (382).

10 Remove the low pressure cont rol valve (383).

Figure 7E5 – 202

11 Remove the manual valve link retainer (380).

12 Remove the manual valve link (379).

13 Remove the manual valve link retainer (378).

14 Remove the manual valve (377).

Figure 7E5 – 203

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 94

7E5 – 94

15 Remove the 1–2 shift solenoid retainer (351).

16 Remove the 1–2 shift solenoid (368).

17 Remove the 1–2 shift control valve retainer (343).

18 Remove the 1–2 shift control valve spring (3 67).

19 Remove the 1–2 shift control valve (366).

Figure 7E5 – 204

20 Remove the 2–3 shift solenoid retainer (351).

21 Remove the 2–3 shift solenoid (369).

22 Remove the 2–3 shift control valve (370).

23 Remove the 2–3 shift valve (371).

24 Remove the 2–3 shift valve spring (372).

Figure 7E5 – 205

25 Remove the 4–5 shift solenoid retainer (351).

26 Remove the 4–5 shift solenoid (376).

27 Remove the 4–5 shift control valve (375).

28 Remove the 4–5 shift valve (374).

29 Remove the 4–5 shift valve spring (373).

Figure 7E5 – 206

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 95

7E5 – 95

Rear Control Valve Body Assemble

1 Install the 4–5 shift valve spring (373).

2 Install the 4–5 shift valve (374).

3 Install the 4–5 shift control valve (375).

4 Install the 4–5 shift solenoid (376).

5 Install the 4–5 shift solenoid retainer (35 1).

Figure 7E5 – 207

6 Install the 2–3 shift valve spring (372).

7 Install the 2–3 shift valve (371).

8 Install the 2–3 shift control valve (370).

9 Install the 2–3 shift solenoid (369).

10 Install the 2–3 shift solenoid retainer (35 1).

Figure 7E5 – 208

11 Install the 1–2 shift control valve (366).

12 Install the 1–2 shift control valve spring (367).

13 Install the 1–2 shift control valve retainer (34 3).

14 Install the 1–2 shift solenoid (368).

15 Install the 1–2 shift solenoid retainer (35 1).

Figure 7E5 – 209

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 96

7E5 – 96

16 Install the manual valve link retainer (378) to the

manual valve (377).

17 Install the manual valve link (379) to the manual valve

(377).

18 Install the manual valve link retainer (380) to the

manual valve (377).

19 Install the manual valve (377) sub-assem bly, to the

rear control valve body.

Figure 7E5 – 210

20 Install the low pressure control valve (383).

21 Install the low pressure control valve spring (382).

22 Install the bore plug (381).

23 Install the low pressure control valve bore retainer

(384).

Figure 7E5 – 211

24 Install the reverse lock out valve (385).

25 Install the reverse lock out spring (386).

26 Install the reverse lock out valve retainer (343).

Figure 7E5 – 212

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 97

7E5 – 97

27 Install the 1–2 shift valve (387).

28 Install the 1–2 shift valve spring (388).

29 Install the 1–2 shift valve retainer (343).

Figure 7E5 – 213

Front Control Valve Body Inspection

1 Inspect the front control valve body (340) for the

following conditions:

• Damaged or porous casting.

• Damaged sealing surfaces.

• Debris in fluid passages.

2 Use a small pick or screwdriver , before disassembly,

to inspect the front control valve bod y (340)

components for the following conditions:

• Valves binding or sticking in their bores or

bushings.

• Broken missing or damaged springs.

• Missing or damaged retainers.

• Damaged solenoid valves.

• Debris in valve line ups or solenoid valves.

3 During disassembly, inspect the front control valve

body for the following conditions:

• Worn or damaged valves, valve bores or

bushings.

• Broken, missing or damaged springs.

• Missing or damaged retainers.

• Damaged solenoid valves.

• Debris in valve line ups or solenoid valve.

Figure 7E5 – 214

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 98

7E5 – 98

Front Control Valve Body Disassemble

1 Remove the safety mode valve retainer (343).

2 Remove the safety mode valve spring (342).

3 Remove the safety mode valve (341).

Figure 7E5 – 215

4 Remove the 3–4 shift valve retainer (343).

5 Remove the 3–4 shift valve spring (344).

6 Remove the 3–4 shift valve (345).

7 Remove the 3–4 shift control valve (346).

Figure 7E5 – 216

8 Remove the TCC PWM solenoid valve retainer (351).

9 Remove the TCC PWM solenoid (352).

10 Remove the TCC regulator apply valve (348).

11 Remove the TCC regulator apply valve spring (347).

Figure 7E5 – 217

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 99

7E5 – 99

12 Remove the feed limit valve retainer (343).

13 Remove the feed limit valve spring (354).

14 Remove the feed limit valve (353).

Figure 7E5 – 218

15 Remove the pressure control solenoid retainer (351).

16 Remove the pressure control solenoid (357).

Figure 7E5 – 219

Front Control Valve Body Assemble

1 Install the pressure control solenoid (35 7).

2 Install the pressure control solenoid retainer (351).

Figure 7E5 – 220

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 100

7E5 – 100

3 Install the feed limit valve (353).

4 Install the feed limit valve spring (354).

5 Install the feed limit valve retainer (343).

Figure 7E5 – 221

6 Install the TCC PWM solenoid valve spring (347).

7 Install the TCC regulator apply valve (348).

8 Install the TCC PWM solenoid (352).

9 Install the TCC PWM solenoid retainer (351).

Figure 7E5 – 222

10 Install the 3–4 shift control valve (346).

11 Install the 3–4 shift valve (345).

12 Install the 3–4 shift valve spring (344).

13 Install the 3–4 shift control valve retainer (34 3).

Figure 7E5 – 223

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 101

7E5 – 101

14 Install the safety mode valve (341).

15 Install the safety mode valve spring (342).

16 Install the safety mode valve retainer (343).

Figure 7E5 – 224

Control Valve Body and Accumulator Assembly

Assemble

1 Install guide pins, Tool J 39068 (or 6 mm ro d, 75 mm

in length) into the front and rear control va lve bodies,

in the positions shown.

2 Install NEW control valve body spacer plate gasket

(309) onto the valve bodies.

3 Install NEW solenoid valve filter assemb lies (308, 312)

onto the control valve body spacer plate (307).

4 Install the control valve bod y spacer p late (3 07) onto

the valve bodies.

Figure 7E5 – 225

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 102

7E5 – 102

5 Use petroleum jelly to install and hold the 12

checkballs (306) into the spacer plate (3 04), in the

positions shown.

Figure 7E5 – 226

6 Install the new control valve body gasket (30 5) onto

the spacer plate (307).

7 Install the control valve body channel plate (304).

Figure 7E5 – 227

8 Use petroleum jelly to install a nd hold the control valve

channel plate check ball spring (302) onto the channel

plate (304).

9 Install the NEW control valve bod y channel plate

gasket (303) onto the channel plate (304).

10 Install the control valve channel plate (301) onto the

channel plate gasket (303).

Figure 7E5 – 228

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 103

7E5 – 103

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

11 Install the control valve body bolts (50, 300) i nto the

valve body and tighten to the correct torque

specifications.

Front valve body to channel plate bolt (50)

torque specification..............................................11 N.m

Channel plate to front and rear valve body

bolt (300) torque specification..............................11 N.m

12 Remove the guide pins, Tool J 39068 from the valve

body (47).

Figure 7E5 – 229

13 Install the direct clutch accumulator p iston flu id seal

rings (314, 316) onto the direct clutch accumulator

piston (315).

14 Install the direct clutch accumulator p iston (3 15) into

the direct clutch accumulator housing (317).

Figure 7E5 – 230

15 Install the overdrive clutch accumul ator pisto n fluid

seal rings (320, 322) onto the overdrive clutch

accumulator piston (321).

16 Install the overdrive accumulator piston (321) into the

overdrive clutch accumulator housing (323).

Figure 7E5 – 231

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 104

7E5 – 104

17 Install the intermediate clutch accumulator fluid seal

rings (325, 327) onto the intermediate clutch

accumulator piston (326).

18 Install the intermediate clutch accumulator piston (326)

into the intermediate clutch accumulator ho using

(328).

Figure 7E5 – 232

19 Install the 2nd clutch accumulator piston fluid seal

rings (330, 332) onto the 2nd clutch accum ul ator

piston (331).

20 Install the 2nd clutch accumulator piston (331) into the

2nd clutch accumulator housing (333).

Figure 7E5 – 233

21 Install the direct clutch accumulator spring (313).

22 Install the direct clutch accumulator h ousing (317) onto

the valve body (47).

23 Install the direct clutch accumulator h ousing bolts

(318) into the front valve body (47) and tighten to the

correct torque specification.

Direct clutch accumulator housing to front

valve body bolt torque specification.....................11 N.m

Figure 7E5 – 234

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 105

7E5 – 105

24 Install the overdrive clutch accumul ator spri ng (319).

25 Install the overdrive clutch accumul ator hou sing (323)

onto the front valve body (47).

26 Install the overdrive clutch accumul ator hou sing bolts

(318) into the valve body (47) and tighten to the

correct torque specification.

Overdrive clutch accumulator housing to front

valve body bolt torque specification.....................11 N.m

Figure 7E5 – 235

27 Install the intermediate clutch accumulator spring

(324).

28 Install the intermediate clutch accumulator housing

(328) onto the valve body (47).

29 Install the intermediate clutch accumulator housing

bolts (318) into the rear valve body (47) and tighten to

the correct torque specification.

Intermediate clutch accumulator housing to rear

valve body bolt torque specification.....................11 N.m

Figure 7E5 – 236

30 Install the 2nd clutch accumulator spring (32 9).

31 Install the 2nd clutch accumulator housing (333) onto

the valve body (47).

32 Install the 2nd clutch accumulator housing bolts (318)

into the valve body (47).

2nd clutch accumulator housing to rear

valve body bolt torque specification.....................11 N.m

Figure 7E5 – 237

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 106

7E5 – 106

1.40 Input Speed Sensor Installation

1 Rotate the transmission 90 degrees.

2 Install the input speed sensor (44) into the case (24).

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

3 Install the input speed sensor screw (45) into the case

(24) and tighten to the correct torque specification.

Input speed sensor to transmission case

bolt torque specification.......................................11 N.m

Figure 7E5 – 238

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 107

7E5 – 107

1.41 Output Shaft Speed Sensor Installation

1 Install the output speed sensor (42) into the case (24).

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

2 Install the output speed sensor screw (43) into the

case (24) and tighten to the correct torque

specification.

Output speed sensor to transmission case

bolt torque specification......................................11 N.m.

Figure 7E5 – 239

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 108

7E5 – 108

1.42 Control Valve Body and Accumulator

Assembly

Reinstall

1 Install a NEW overdrive clutch fluid passa ge sleeve

(39) into the case (24).

2 Install a NEW centre support fluid passage sleeve (38)

into the case (24).

Figure 7E5 – 240

3 Install the control valve body and accumulator

assembly (47) onto the case (24), ensuring that the

manual valve link engag es the manual shaft detent

lever locating pin.

4 Install the detent lever spring (52), ensuring that the

detent spring roller is properly engaged with the

manual shift shaft switch.

5 Install the control valve body bolts (53) into the case

(24) and hand tighten.

Figure 7E5 – 241

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 109

7E5 – 109

6 Install the control valve body and accumulator

assembly bolts (49, 51) into the case (24) and hand

tighten.

Figure 7E5 – 242

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

7 Tighten the control valve bo dy and accumulator to

case bolts (49, 50, 51) in the correct sequence as

shown and to the correct torque specificatio n.

Control valve body and accumulator to

transmission case bolt torque

specification.........................................................11 N.m

Figure 7E5 – 243

8 Install a 0.8 mm spacer (A) between the manual shaft

detent lever (600) and the manual shaft detent lever

spring (52).

9 Tighten the manual shaft detent lever spri ng and

control valve body to transmission case bolts (53) to

the correct torque specification.

Manual shaft detent lever spring and

control valve body to transmission

case bolt torque specification...............................11 N.m

10 Remove the spacer (A).

Figure 7E5 – 244

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 110

7E5 – 110

1.43 Wiring Harness

Reinstall

1 Install the wiring harness connector (55) thru the case

(24). Hold the connector and install the wiring harness

connector retainer (54).

Figure 7E5 – 245

2 Route the harness to the valve body a nd connect the

following components:

• Pressure Control Solenoid (357).

• TCC PWM Solenoid (352).

• 1–2 Shift Solenoid (368).

• 2–3 Shift Solenoid (369).

• 4–5 Shift Solenoid (376).

• Internal Mode Switch – IMS (602).

• Input Speed Sensor (44).

• Output Speed Sensor (42).

Figure 7E5 – 246

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 111

7E5 – 111

1.44 Pan and Filter Assembly

Reinstall

1 Inspect the following components:

• Transmission fluid pan (62) for distortion, cracks,

score marks

• Inspect the fluid pan bolts (65) for thread

damage

• Inspect the transmission pan magnet (61) for

cracks and tears

2 Install the transmission fluid filt er (59) and fluid filters

seals (57) into the case (24).

Figure 7E5 – 247

3 Install the NEW drain plug seal (64) into the fluid pan

drain plug (63).

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

4 Install the NEW fluid pan dra in plug (63) and tighten to

the correct torque specification.

Fluid pan drain plug torque specification..............20 N.m

5 Install the fluid pan magn et (61) onto the fluid pan

(62).

6 Install the NEW fluid pan gasket (60) onto the flui d pan

(62).

7 Install the fluid pan (62) onto t he case (24).

8 Install the fluid pan bolts (65) into the case (24) and

tighten to the correct torque specification.

Fluid pan to transmission case

bolt torque specification.......................................11 N.m

Figure 7E5 – 248

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 112

7E5 – 112

1.45 Extension Housing

Reinstall

1 Inspect both inner (26) and outer (28) output shaft

bearings for the following:

• Damaged cage.

• Roller pitted.

2 Use Tool J 5590 to remove the outer output shaft

bearing if it is damaged.

Figure 7E5 – 249

3 Place Tool J 45131-1 onto the inner output shaft

bearing (26). Place the case extension on Tool J

45131-2.

4 Insert Tool J 7079-2 into Tool J 45131-1 and remove

the inner output shaft bearing (26).

Figure 7E5 – 250

5 Install driver, Tool J 8092 into installer, Tool J 44762,

then install the outer output shaft bearing (28) into the

extension housing, with numbers on the bearing facing

up.

Figure 7E5 – 251

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 113

7E5 – 113

6 Reverse the extension ho using position, then with

driver, Tool J 8092 installed into installer, Tool J 44762

press the inner output shaft bearing (26) i nto the

extension housing, with numbers on bearing facing up.

Figure 7E5 – 252

7 Rotate the transmission 90 degrees with the output

shaft facing upward.

8 Measure from the bottom of the transmission case to

the face of the output shaft. Record this as Dimension

'B'. Refer to following Output Shaft End Play Chart to

determine the correct washer size.

OUTPUT SHAFT END PLAY CHART

Dimension B Washer Thickness (mm)

15.99 mm–16.27 mm 0.95–1.05

16.27 mm–16.47 mm 1.15–1.25

16.47 mm–16.67 mm 1.35–1.45

16.67 mm–16.87 mm 1.55–1.65

16.87 mm–17.07 mm 1.75–1.85

17.07 mm–17.27 mm 1.95–2.05

17.27 mm–17.47 mm 2.15–2.25

17.47 mm–17.67 mm 2.35–2.45

17.67 mm–17.87 mm 2.55–2.65

17.87 mm–18.07 mm 2.75–2.85

Figure 7E5 – 253

9 Install the input and reaction c arrier washer (22).

10 Install the input and reaction c arrier thrust be aring (23)

onto the extension housing.

Figure 7E5 – 254

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 114

7E5 – 114

11 Install the extension housing gasket (25) onto the

extension housing (27).

12 Install the extension housing (27) onto the case (24).

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes in this Service Information.

13 Install the extension housing bolts (35) and tighten to

the correct torque specification.

Extension housing to transmission case

bolt torque specification.......................................22 N.m

Figure 7E5 – 255

14 Using suitable snap ring pliers, install a NEW output

shaft snap ring retainer (3), refer to Figure 7E5-257.

Install the seal onto the tool before installing

into the extension housing to prevent

damage to the seal lips.

15 Using seal installer, Tool J 44765, install the propeller

shaft flange seal (29).

Figure 7E5 – 256

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 115

7E5 – 115

1.46 Propeller Shaft Flange

Reassemble

1 Install the NEW propeller shaft flange O-ring seal (32)

into the prop shaft flange (31).

2 Install the propeller shaft flange (31).

3 Put the transmission in Park.

NOTE

Refer to Fastener note under 4. Safety and

Service Guidelines in Section 00 Warnings,

Cautions and Notes of this Service Information.

4 Install a NEW dished thrust washer (33) and NEW

propeller shaft flange nut (34). Tighten nut to the

correct torque specification.

Propeller shaft flange to output shaft

nut torque specification........................................57 N.m

Figure 7E5 – 257

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 116

7E5 – 116

1.47 Holding Fixture Removal

1 Using suitable lifting equipment, remove the

transmission and the holding fixture, Tool J 8763-B

from the bench bracket, Tool J 3289-20.

2 Remove Tool J 8763-B from the transmissio n.

Figure 7E5 – 258

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 117

7E5 – 117

1.48 Torque Converter Assembly

Reinstall

1 Lubricate a NEW input shaft O-ring seal (43 0) with

transmission fluid and install to the groove provided.

Figure 7E5 – 259

Take care when installing the torque

converter as it is a heavy assembly

(approximately 12 kilograms) and personal

injury may result if lifted incorrectly.

2 Install the torque converter assembly (1).

Figure 7E5 – 260

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 118

7E5 – 118

2 Transmission Reference

Diagrams

Figure 7E5 – 261 Case and Associated Parts (1 of 2)

Legend

1 Torque Converter Assembly 14 Intermediate and Overdrive Clutch Housing Retainer Ring

2 Torque Converter Housing to Main Case Bolt 15 Overdrive Clutch Housing Assembly

3 Torque Converter Housing Assembly 16 Low Clutch Sprag Assembly

4 Torque Converter Housing Fluid Seal Assembly 17 Low Clutch Roller Thrust Bearing

5 Reverse Clutch Housing Thrust Washer – Selective 18 Centre Support

6 Direct and Reverse Clutch Assembly 19 Input and Reaction Carrier Assembly

7 Forward and Coast Clutch Assembly 20 Input and Reaction Carrier Thrust Bearing

8 Input Sun Gear with Forward Clutch Roller Inner Race Shaft 21 Output Shaft Assembly – W/Rear Internal Gear

9 Direct Clutch Hub Thrust Washer 22 Input and Reaction Carrier Washer – Selective

10 Direct Clutch Assembly with Input and Reaction Carrier 23 Input and Reaction Carrier Thrust Bearing

11 Input and Reaction Carrier Inner Shaft Thrust Washer 24 Automatic Transmission Case Assembly

12 Intermediate Clutch Sprag Assembly

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 119

7E5 – 119

Figure 7E5 – 262 Case and Associated Parts (2 of 2)

Legend

24 Automatic Transmission Case Assembly 45 Input Speed Sensor Bolt

25 Automatic Transmission Case Extension Gasket 46 Automatic Transmission Fluid Pump Cover Gasket

26 Output Shaft Bearing 47 Control Valve Body and Accumulator Assembly

27 Automatic Transmission Case Extension 49 Control Valve Body Bolt M6 x 1.0 x 50

28 Output Shaft Bearing 50 Control Valve Body Bolt M6 x 1.0 x 38

29 Automatic Transmission Propeller Shaft Flange Seal 51 Control Valve Body Bolt M6 x 1.0 x 50

30 Output Shaft Assembly Retainer 52 Manual Shaft Detent Assembly

31 Automatic Transmission Propeller Shaft Flange 53 Control Valve Body Bolt M6 x 1.0 x 68

32 Propeller Shaft Flange – O-ring Seal 54 Wiring Harness Clip

33 Automatic Transmission Propeller Shaft Thrust Washer 55 Automatic Transmission Wiring Harness

34 Propeller Shaft Flange Nut 56 Automatic Transmission Wiring Harness – O-ring seal – 2

35 Automatic Transmission Case Extension Bolt 57 Automatic Transmission Filter Seal – 2

36 Automatic Transmission Fluid Level Hole Plug 59 Automatic Transmission Fluid Filter

37 Automatic Transmission Fluid Level Hole Plug O-ring Seal 60 Automatic Transmission Fluid Pan Gasket

38 Centre Support Fluid Passage Sleeve 61 Automatic Transmission Fluid Pan Magnet

39 Overdrive Clutch Fluid Passage Sleeve 62 Automatic Transmission Fluid Pan Assembly

40 Automatic Transmission Pressure Test Plug 63 Automatic Transmission Fluid Pan Drain Plug

41 Output Speed Sensor Spacer 64 Automatic Transmission Fluid Pan Drain Plug Seal

42 Output Speed Sensor 65 Automatic Transmission Fluid Pan Bolt

43 Output Speed Sensor Bolt M6 x 1.0 x 50 66 Automatic Transmission Pressure Test Plug O-ring Seal

44 Input Speed Sensor

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 120

7E5 – 120

Figure 7E5 – 263 Fluid Pu mp Assembly

Legend

200 Reverse Clutch Housing Fluid Seal Ring - 3 221 Automatic Transmission Fluid Pump Vane Ring

201 Input Shaft Bearing Assembly 222 Automatic Transmission Fluid Pump Vane

202 Automatic Transmission Fluid Pump Cover Assembly 223 Automatic Transmission Fluid Pump Rotor – Selective

203 Check Valve Retainer and Ball Assembly 224 Automatic Transmission Fluid Pump Rotor Guide

204 Valve Bushing/Spring Retainer 225 Automatic Transmission Fluid Pump Vane Ring

205 Line Boost Valve Bushing Seal 226 Torque Converter Bushing

206 Line Boost Valve Bushing 227 Torque Converter Housing

207 Line Boost Valve 228 Torque Converter Housing Seal Bolt M4 x 0.7 x 10.0 - 4

208 Line Boost Valve Spring 229 Torque Converter Housing Seal

209 Pressure Regulator Valve Spring 231 Automatic Transmission Fluid Pump Slide Pin Assembly

210 Pressure Regulator Valve 232 Orifice Sleeve

211 Automatic Transmission Fluid Pump Retainer Pin 233 Orifice Cup Plug - 2

212 Automatic Transmission Pump Cover Seal 234 TCC Control Valve Spring

213 Automatic Transmission Fluid Pump Screen Assembly 235 TCC Control Valve

214 Brass Orifice Insert 236 Automatic Transmission Fluid Pump Retainer Pin

215 Turbine Shaft Bushing 237 TCC Enable Valve

216 Automatic Transmission Fluid Pump Slide – Selective 238 Pressure Relief Ball Valve Spring

217 Automatic Transmission Fluid Pump Slide Seal Support 239 Pressure Relief Ball Valve

218 Automatic Transmission Fluid Pump Slide Seal 240 Automatic Transmission Fluid Pump Bolt M6 x 1.0 x 40

219 Automatic Transmission Fluid Pump Slide Ring 241 Automatic Transmission Fluid Pump Bolt M8 x 1.25 x 40

220 Automatic Transmission Fluid Pump Slide Ring 242 Automatic Transmission Fluid Pump Slide O-ring Seal

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 121

7E5 – 121

Figure 7E5 – 264 Control Valve Body and Accumulator Assembly

Legend

300 Control Valve Body Bolt M6 x 1.0 x 38 - 7 317 Direct Clutch Accumulator Housing

301 Control Valve Top Channel Plate 318 Accumulator Housing Bolt M6 x 1.0 x 30 - 12

302 Control Valve Channel Plate Ball Check Spring 319 Overdrive Clutch Accumulator Piston Spring

303 Control Valve Channel Plate Gasket 320 Overdrive Clutch Accumulator Piston Fluid Seal Ring

304 Control Valve Bottom Channel Plate 321 Overdrive Clutch Accumulator Piston

305 Control Valve Body Gasket 322 Overdrive Clutch Accumulator Piston Fluid Seal Ring

306 Control Valve Body Ball Check Valve 323 Overdrive Clutch Accumulator Housing

307 Control Valve Body Spacer Plate 324 Intermediate Clutch Accumulator Piston Spring

308 TCC PWM Solenoid Valve Filter Assembly 325 Intermediate Clutch Accumulator Piston Fluid Seal Ring

309 Control Valve Body Spacer Plate Gasket 326 Intermediate Clutch Accumulator Piston

310 Control Valve Rear Body Assembly 327 Intermediate Clutch Accumulator Piston Fluid Seal Ring

311 Control Valve Front Body Assembly 328 Intermediate Clutch Accumulator Housing

312 Pressure Control Solenoid Valve Filter Assembly 329 2nd Clutch Accumulator Piston Spring

313 Direct Clutch Accumulator Piston Spring 330 2nd Clutch Accumulator Piston Seal Ring

314 Direct Clutch Accumulator Piston Fluid Seal Ring 331 2nd Clutch Accumulator Piston

315 Direct Clutch Accumulator Piston 332 2nd Clutch Accumulator Piston Seal Ring

316 Direct Clutch Accumulator Piston Fluid Seal Ring 333 2nd Clutch Accumulator Housing

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 122

7E5 – 122

Figure 7E5 – 265 Front Co ntrol Valve Body

Legend

340 Front Control Valve Body 349 Solenoid Valve – O-ring Seal

341 Safety Mode Valve 350 Solenoid Valve – O-ring Seal

342 Safety Mode Valve Spring 351 Solenoid Valve Retainer - 2

343 Valve Spring Retainer - 3 352 TCC PWM Solenoid Valve

344 3–4 Shift Valve Spring 353 Feed Limit Valve

345 3–4 Shift Valve 354 Feed Limit Valve Spring

346 3–4 Shift Control Valve 355 Pressure Control Solenoid – O-ring Seal

347 TCC Regulator Apply Valve Spring 356 Pressure Control Solenoid – O-ring Seal

348 TCC Regulator Apply Valve 357 Pressure Control (PC) Solenoid Assembly

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 123

7E5 – 123

Figure 7E5 – 266 Rear Con t ro l Valve Body

Legend

343 Valve Spring Retainer 375 4–5 Shift Control Valve

349 Solenoid Valve – O-ring Seal 376 4–5 Shift Solenoid (SS) Valve Assembly

350 Solenoid Valve – O-ring Seal 377 Manual Valve

351 Solenoid Valve Retainer 378 Manual Valve Link Washer – Waved

365 Rear Control Valve Body 379 Manual Valve Link

366 1–2 Shift Control Valve 380 Manual Valve Link Retainer

367 1–2 Shift Control Valve Spring 381 Low Pressure Control Valve Bore Plug

368 1–2 Shift Solenoid (SS) Valve Assembly 382 Low Pressure Control Valve Spring

369 2–3 Shift Solenoid (SS) Valve Assembly 383 Low Pressure Control Valve

370 2–3 Shift Control Valve 384 Low Pressure Control Valve Bore Retainer

371 2–3 Shift Valve 385 Reverse Lockout Valve

372 2–3 Shift Valve Spring 386 Reverse Lockout Valve Spring

373 4–5 Shift Valve Spring 387 1–2 Shift Valve

374 4–5 Shift Valve 388 1–2 Shift Valve Spring

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 124

7E5 – 124

Figure 7E5 – 267 Direct and Reverse Clutch Assembly

Legend

400 Reverse Clutch Housing Bushing 411 Direct Clutch Plate Assembly – Outer Spline

401 Reverse Clutch – W/Input Housing Assembly 412 Direct Clutch Plate Assembly – In ner Spline

402 Reverse Clutch Piston Inner Seal 413 Direct Clutch Backing Plate

403 Reverse Clutch Housing Ball Check Valve 414 Direct Clutch Backing Plate Retainer Ring – Selective

404 Reverse Clutch Piston 415 Reverse Clutch Spacer

405 Direct Clutch Housing Ball Check Valve 416 Reverse Clutch Apply Plate

406 Direct Clutch Piston Assembly 417 Reverse Clutch Plate Assembly – Outer Spline

407 Direct and Reverse Clutch Spring 418 Reverse Clutch Plate Assembly – Inner Spline

408 Direct and Reverse Clutch Spring Retainer 419 Reverse Clutch Backing Plate

409 Direct and Reverse Clutch Spring Retainer Ring 420 Reverse Clutch Backing Plate Retainer Ring – Selective

410 Direct Clutch Apply Plate

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 125

7E5 – 125

Figure 7E5 – 268 Forward and Coast Clutch Assembly

Legend

430 Input Shaft – O-ring Seal 441 Coast Clutch Spacer Plate – Selective

431 Input Shaft Fluid Seal Ring 442 Coast Clutch Apply Plate

432 Input Shaft Fluid Seal Ring – 3 places 443 Coast Clutch Plate Assembly – Outer Spline

433 Forward Clutch – W/Input Housing Assembly 444 Coast Clutch Plate Assembly – Inner Spline

434 Forward Clutch Housing Ball Check Valve Assembly 445 Coast Clutch Backing Plate

435 Forward Clutch Bushing 446 Coast Clutch Housing

436 Forward Clutch Piston Assembly 447 Forward Clutch Apply Plate

437 Coast Clutch Piston Ball Check Valve Assembly 448 Forward Clutch Plate Assembly – Outer Spline

438 Coast Clutch Piston Assembly 449 Forward Clutch Plate Assembly – Inner Spline

439 Forward and Coast Clutch Spring 450 Forward Clutch Backing Plate

440 Forward and Coast Clutch Spring Retainer Ring 451 Forward Clutch Backing Plate Retainer Ring – Selective

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 126

7E5 – 126

Figure 7E5 – 269 Input Sun Gear and Forward Sprag Clutch Assembly

Legend

455 Forward Clutch Roller Inner Race Thrust Ring 459 Forward Clutch Sprag Outer Race

456 Forward Clutch Roller Inner Bearing 460 Forward Clutch Sprag Assembly Retainer Rings - 2

457 Input Sun Gear Shaft Assembly 461 Forward Clutch Sprag Assembly

458 Forward Clutch Roller Outer Race Washer 462 Orificed Cup Plug – Lube

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 127

7E5 – 127

Figure 7E5 – 270 Direct Clutch Drum and Shaft Assembly

Legend

465 Input and Reaction Carrier Bushing- 2 466 Direct Clutch Drum

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 128

7E5 – 128

Figure 7E5 – 271 Intermediate Sprag Clutch Assembly

Legend

470 Overdrive and Reverse Clutch – W/Hub Assembly 474 Intermediate Clutch Sprag Outer Race

471 Intermediate Clutch Roller Thrust Washer 475 Intermediate Clutch Roller Thrust Washer

472 Intermediate Clutch Sprag Assembly Retainer Rings - 2 476 Intermediate Clutch Roller Thrust Bearing

473 Intermediate Clutch Sprag Assembly 477 Intermediate Clutch Roller Thrust Bearing Retainer

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 129

7E5 – 129

Figure 7E5 – 272 Overdrive and Intermediate Clutch Assembly

Legend

480 Overdrive Clutch Backing Plate Retainer Ring – Selective 489 Intermediate Clutch Backing Plate

481 Overdrive Clutch Backing Plate 490 Intermediate Clutch Plate Assembly – Inner Spline

482 Overdrive Clutch Plate Assembly – Inner Spline 491 Intermediate Clutch Plate Assembly – Outer Spline

483 Overdrive Clutch Plate Assembly – Outer Spline 492 Intermediate Clutch Apply Plate

484 Overdrive Clutch Spacer 493 Overdrive Clutch Housing

485 Overdrive Clutch Spring Retainer Ring 494 Intermediate Clutch Spring

486 Overdrive Clutch Piston Spring 495 Intermediate Clutch Piston Assembly

487 Overdrive Clutch Piston Assembly 496 Intermediate Clutch Housing

488 Intermediate Clutch Backing Plate Retainer Ring – Selective 497 Intermediate Clutch Housing Retainer Ring

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 130

7E5 – 130

Figure 7E5 – 273 Low Clutch Sprag Assembly

Legend

500 Low Clutch Roller Retainer 503 Low Clutch Sprag Assembly

501 Low Clutch Roller Thrust Washer 504 Low Clutch Sprag Outer Race

502 Low Clutch Sprag Assembly Retainer Rings - 2 505 Low Clutch Sprag Inner Race

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 131

7E5 – 131

Figure 7E5 – 274 Centre Support Assembly

Legend

510 Low and Reverse Clutch Plate Retainer Ring – Selective 523 2nd Clutch Apply Plate

511 Low and Reverse Clutch Backing Plate 524 2nd Clutch Plate Assembly – Outer Spline

512 Low and Reverse Clutch Plate Assembly – Inner Spline 525 2nd Clutch Plate Assembly – Inner Spline

513 Low and Reverse Clutch Plate Assembly – Outer Spline 526 2nd Clutch Backing Plate

514 Low and Reverse Clutch Apply Plate 527 2nd Clutch Backing Plate Retainer Ring – Selective

515 Low and Reverse Clutch Spring Retainer Ring 528 2nd Coast Clutch Piston Assembly

516 Low and Reverse Clutch Spring 529 2nd Coast Clutch Spring

517 Low and Reverse Clutch Piston 530 2nd Coast Clutch Spring Retainer Ring

518 Centre Support 531 2nd Coast Clutch Spacer

519 Input and Reaction Bearing Assembly 532 2nd Coast Clutch Plate Assembly – Outer Spline

520 2nd Clutch Piston 533 2nd Coast Clutch Plate Assembly – Inner Spline

521 2nd Clutch Spring 534 2nd Coast Clutch Backing Plate

522 2nd Clutch Spring Retainer Ring 535 2nd Coast Clutch Plate –Backing Plate – Retainer Ring

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 132

7E5 – 132

Figure 7E5 – 275 Planetary Carrier Assembly

Legend

540 Input and Reaction Carrier Outer Retainer Ring 548 Input and Reaction Carrier Bushing

541 Input and Reaction Bearing Assembly 549 2nd Clutch Sprag Inner Race

542 2nd Clutch Roller Inner Race Bearing Assembly 550 Reaction Internal Gear

543 2nd Clutch Sprag Retainer 551 Reaction Internal Gear Flange Washer

544 2nd Clutch Roller Outer Race Washer 552 Reaction Carrier Bushing – 2

545 2nd Clutch Sprag Outer Race 553 Input and Reaction Carrier

546 2nd Clutch Sprag Assembly Retainer - 2 554 Input and Reaction Bearing Assembly

547 2nd Clutch Sprag Assembly

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 133

7E5 – 133

Figure 7E5 – 276 Rear Internal Gear Output Sh aft Assembly

Legend

560 Rear Internal Gear 563 Rear Internal Retainer Ring

561 Input and Reaction Carrier Bushing 564 Cup Plug

562 Output Shaft Assembly

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 134

7E5 – 134

Figure 7E5 – 277 Park Pawl Assembly

Legend

24 Transmission Case 608 Park Pawl Actuator Bracket (Outer)

600 Manual Shaft Detent Lever 609 Park Pawl Actuator Bracket Bolt M8 x 1.25 x 25 - 2

601 Manual Shaft Detent Lever Pin 610 Park Pawl Shaft

602 Transmission Manual Shift Shaft Switch Assembly 611 Park Pawl Spring

605 Manual Shift Shaft Seal 612 Park Pawl

606 Manual Shift Shaft 613 Park Pawl Actuator Assembly

607 Park Pawl Actuator Bracket (Inner)

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 135

7E5 – 135

Figure 7E5 – 278 Automatic Transmission Electronic Component Locations

Legend

42 Output Speed Sensor (OSS) 368 1–2 Shift Solenoid (SS) Valve Assembly

44 Input Speed Sensor (ISS) 369 2–3 Shift Solenoid (SS) Valve Assembly

55 Transmission Fluid Temperature (TFT) Sensor 376 4–5 Shift Solenoid (SS) Valve Assembly

352 TCC PWM Solenoid Valve 602 Transmission Manual Shift Shaft Switch Assembly

357 Pressure Control Solenoid (PCS) Assembly

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 136

7E5 – 136

Figure 7E5 – 279 Bushing and Bearing Locations

Legend

17 Low Clutch Roller Thrust Bearing 465 Input and Reaction Carrier Bushing Assembly - 2

20 Input and Reaction Carrier Thrust Bearing 473 Intermediate Clutch Sprag Assembly

23 Input and Reaction Carrier Thrust Bearing 476 Inte rmediate Clutch Roller Thrust Bearing Assembly

26 Output Shaft Bearing 503 Low Clutch Sprag Assembly

28 Output Shaft Bearing 519 Input and R eaction Bearing Assembly

201 Input Shaft Bearing Assembly 541 Input and Reaction Bearing Assembly

215 Turbine Shaft Bushing 542 2nd Clutch Roller Inner Race Bearing Assembly

226 Torque Converter Bushing 547 2nd Clutch Sprag Assembly

400 Reverse Clutch Housing Bushing 548 Input and Reaction Carrier Bushing

435 Forward Clutch Bushing 552 Reaction Carrier Bushing - 2

456 Forward Clutch Roller Inner Bearing 554 Input and Reaction Bearing (561) and Carrier Bushing

461 Forward Clutch Sprag Assembly 561 Input and Reaction Carrier Bushing

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 137

7E5 – 137

Figure 7E5 – 280 Seal Locations

Legend

4 Torque Converter Housing Fluid Seal Assembly 402 Reverse Clutch Piston Inner Seal

29 Transmission Propeller Shaft Flange Seal 404 Reverse Clutch Piston

32 Transmission Propeller Shaft Flange – O-ring Seal 406 Direct Clutch Piston Assembly

38 Centre Support Fluid Passage Sleeve 430 Input Shaft – O-ring Seal

39 Overdrive Clutch Fluid Passage Sleeve 431 Input Shaft Fluid Seal Ring

56 A/Transmission Wiring Harness – O-ring Seal – 2 432 Input Shaft Fluid Seal Ring - 3

57 Automatic Transmission Filter Seal – 2 436 Forward Clutch Piston Assembly

64 Automatic Transmission Fluid Pan Drain Plug Seal 438 Coast Clutch Piston Assembly

200 Reverse Clutch Housing Fluid Seal Ring - 3 487 Overdrive Clutch Piston Assembly

218 Automatic Transmission Fluid Pump Slide Seal 495 Intermediate Clutch Piston Assembly

220 Automatic Transmission Fluid Pump Slide Ring 517 Low and Reverse Clutch Piston

229 Torque Converter Housing Seal 520 2nd Clutch Piston

242 Automatic Transmission Fluid Pump Slide O-ring Seal 528 2nd Coast Clutch Piston Assembly

314 Clutch Accumulator Piston Fluid Seal Ring 605 Manual Shift Shaft Seal

316 Clutch Accumulator Piston Fluid Seal Ring

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 138

7E5 – 138

3 Specifications

General

Type......................................................................................................... Hydra-matic 5L40–E

Transmission Model Application HFV6 3.6 litre Petrol (P/O LY7).................................5HAG

HFV6 2.8 litre Petrol (P/O LP1).................................5HEG

Special Features....Electronically controlled shift pattern, feel and torque converter operation

Selector Location................................................................................. Floor mounted console

Transmission Weight Dry.................................................................................................73 kg

Transmission Net Weight..............................................................................................80.5 kg

Gear Ratios

Park (P) ..................................................................................................................................–

Reverse (R) ....................................................................................................................3.03:1

Neutral (N)..............................................................................................................................–

5th Gear..........................................................................................................................0.75:1

4th Gear..........................................................................................................................1.00:1

3rd Gear .........................................................................................................................1.60:1

2nd Gear.........................................................................................................................2.21:1

1st Gear..........................................................................................................................3.42:1

Shift Speeds

Refer to charts in Section 7E3 Automatic Transmission – 5L40-E – Hydraulic/Mechanical Diagnosis.

Fluid Pressure

Refer to procedure in Section 7E3 Automatic T r ansmission – 5L40-E – Hydraulic/Mechanical Diagnosis.

Torque Converter

Number of Elements..................................................................3 plus torque converter clutch

Maximum Torque Ratio at Stall HFV6 3.6 litre petrol engine (P/O LY7).........1.90:1 (k=149)

HFV6 2.8 litre petrol engine (P/O LP1).........1.76:1 (k=163)

Nominal Diameter HFV6 3.6 litre petrol engine (P/O LY7)...................258 mm

HFV6 2.8 litre petrol engine (P/O LP1)...................245 mm

Automatic Transmission Fluid

Type Recommended ..............................................................................................Dexron® III

Level Check.....Refer to Section 7E4 Automatic Transmission – 5L40 – On-Vehicle Servicing

Refill (Approximate for an 'On-Car' situation).............................................................. 4.6 litres

Complete Overhaul (Dry)............................................................................................ 8.5 litres

Direct Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (5HAG) .........................................5

(5HEG) .........................................4

External Splines – Steel/Composition Combination (5HAG) .........................................5

(5HEG) .........................................4

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.41 – 1.86 mm

Refer to checking procedure in 1.32 Direct and Reverse Clutch – Reassemble in this Section

Techline

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 139

7E5 – 139

Reverse Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (All Models).....................................3

External Splines – Steel/Composition Combination (All Models) ...................................3

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................0.98 – 1.43 mm

Refer to checking procedure in 1.32 Direct and Reverse Clutch – Reassemble in this Section

Coast Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (All Models).....................................3

External Splines – Steel/Composition Combination (All Models) ...................................3

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.17 – 1.93 mm

Refer to checking procedure in 1.31 Forward and Coast Clutch – Reassemble in this Section

Forward Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (5HAG) .........................................4

(5HEG) .........................................3

External Splines – Steel/Composition Combination (5HAG) .........................................5

(5HEG) .........................................3

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.20 – 1.65 mm

Refer to checking procedure in 1.31 Forward and Coast Clutch – Reassemble in this Section

Overdrive Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (All Models).....................................3

External Splines – Steel/Composition Combination (All Models) ...................................3

Belleville (waved) .............................................................................................................none

Backing Plate .........................................................................................................................1

Clutch Travel Specification .............................................................................1.60 – 2.05 mm

Refer to checking procedure in 1.27 Overdri v e and Intermediate Clutch – Reassemble in this Section

Intermediate Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (5HAG) .........................................4

(5HEG) .........................................3

External Splines – Steel/Composition Combination (5HAG) .........................................4

(5HEG) .........................................3

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.13 – 1.58 mm

Refer to checking procedure in 1.27 Overdri v e and Intermediate Clutch – Reassemble in this Section

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 140

7E5 – 140

Low and Reverse Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination ........................................................5

External Splines – Steel/Composition Combination.......................................................5

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.72 – 2.17 mm

Refer to checking procedure in 1.25 Ce ntre Support – Reassemble in this Section

2nd Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (All Models).....................................5

External Splines – Steel/Composition Combination (All Models) ...................................5

Belleville (waved)....................................................................................................................1

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................1.47 – 1.92 mm

Refer to checking procedure in 1.25 Ce ntre Support – Reassemble in this Section

Second Coast Clutch

Type................................................................................................................Multiple wet disc

Clutch Pack

Internal Splines – Steel/Composition Combination (5HAG) .........................................3

(5HEG) .........................................2

External Splines – Steel/Composition Combination (5HAG) .........................................3

(5HEG) .........................................2

Belleville (waved)..............................................................................................................none

Backing Plate..........................................................................................................................1

Clutch Travel Specification ..............................................................................0.94 – 1.39 mm

Refer to checking procedure in 1.25 Ce ntre Support – Reassemble in this Section

Output Shaft End Play

Refer to procedure in 1.45 Extension Ho using – Reinstall in this Section.

Dimension B Washer Thickness (mm)

15.99 mm–16.27 mm 0.95–1.05

16.27 mm–16.47 mm 1.15–1.25

16.47 mm–16.67 mm 1.35–1.45

16.67 mm–16.87 mm 1.55–1.65

16.87 mm–17.07 mm 1.75–1.85

17.07 mm–17.27 mm 1.95–2.05

17.27 mm–17.47 mm 2.15–2.25

17.47 mm–17.67 mm 2.35–2.45

17.67 mm–17.87 mm 2.55–2.65

17.87 mm–18.07 mm 2.75–2.85

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 141

7E5 – 141

Reverse Clutch Housing Selective Thrust Washer Chart

Refer to procedure in 1.37 Torque Converter Housing – Reinstall in this Section.

Dimension X Washer Thickness (mm)

50.18 mm–50.36 mm 2.53–2.68

50.36 mm–50.54 mm 2.71–2.86

50.54 mm–50.72 mm 2.89–3.04

50.72 mm–50.90 mm 3.05–3.20

50.90 mm–51.08 mm 3.25–3.40

51.08 mm–51.26 mm 3.43–3.58

51.26 mm–51.44 mm 3.61–3.76

51.44 mm–51.62 mm 3.79–3.94

Fluid Pump Clearance Specifications

Refer to procedure in 1.36 Fluid Pump – Re assemble in this Section.

NOTE

• Rotor and slide must be chosen from the

same size classification as the fluid pump

body.

• Allowable rotor and slide to fluid pump body

end play is as follows:

Rotor and Slide to Fluid Pump Body End Play

Slide to Fluid Pump Body End Pla y – 0.030–0.051 mm

Rotor to Fluid Pump Body End Pla y –0.030 –0.051 mm

The fluid pump assembly has a selectiv e rotor and slide components. These compone nts are chosen based on pump

body dimensions. Fluid pump rotor and slide components ar e available in five size classifications (1, 2, 3, 4, and 5) with

the following tolerances.

Rotor Selection Slide Selection Fluid Pump Body Depth

1 17.948–17.961 mm 1 17.948–17.961 mm 1 17.978–18.012 mm

2 17.961–17.974 mm 2 17.961–17.974 mm 2 17.978–18.025 mm

3 17.974–17.987 mm 3 17.974–17.987 mm 3 18.004–18.038 mm

4 17.987–18.000 mm 4 17.987–18.000 mm 4 18.017–18.051 mm

5 18.000–18.013 mm 5 18.000–18.013 mm 5 18.030–18.064 mm

Intermediate and Overdrive Clutch Housing Retainer Ring Specification

Refer to procedure in 1.27 Overdrive and Intermediate Clutch – Reassemble in this Section.

Dimension M Retainer Ring Thickness (mm)

0.75 mm–0.85 mm 3.90–4.00

0.85 mm–0.95 mm 3.80–3.90

0.95 mm–1.05 mm 3.70–3.80

1.05 mm–1.15 mm 3.60-3.7 0

1.15 mm–1.25 mm 3.50–3.60

1.25 mm–1.35 mm 3.40–3.50

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 142

7E5 – 142

Electrical Component Resistance Specifications

Component Circuit

Number Wire

Colour

Inline

Connector

Resistance at

20°C Resistance at

70°C

Resistance to

Ground –

Transmission Case

1525 WH 17

1 – 2 Shift

Solenoid Valve 1222 BK 14 15.0 – 17.0 Ω 17.9 – 20.3 Ω Greater than 50 kΩ

1525 WH 17

2 – 3 Shift

Solenoid Valve 1223 BU 9 15.0 – 17.0 Ω 17.9 – 2 0.3 Ω Greater than 50 kΩ

1525 WH 17

4 – 5 Shift

Solenoid Valve 898 GY 5 15.0 – 1 7.0 Ω 17.9 – 20.3 Ω Greater than 50 kΩ

1228 GN 13

Pressure Control

Solenoid Valve 1229 WH 8 3.5 – 4.6 Ω 4.2 – 5.5 Ω Greater than 50 kΩ

1525 WH 17

TCC PWM

Solenoid Valve 422 YE 20 10.0 – 1 1.5 Ω 11.8 – 13.6 Ω Greater than 50 kΩ

1230 YE 18

Input Speed

Sensor 1231 WH 15 325 – 485 Ω 385 – 575 Ω Greater than 50 kΩ

400 OR 1

Output Speed

Sensor 401 WH 3 325 – 485 Ω 385 – 575 Ω Greater than 50 kΩ

1227 RD 10

TFT Sensor 2762 WH 6 Refer to following chart for TFT Sensor Resistance

Specifications

All wire colours are internal to the transmission

Transmission Fluid Temperature (TFT) Sensor Resistance Specifications

Temperature °C Minimum

Resistance Ω Nominal

Resistance Ω Maximum

Resistance Ω

-40 89 500 100 000 110 500

-30 46 419 51 400 56 381

-20 25 120 27 610 30 100

-10 14 160 15 450 16 740

0 8 278 8 972 9 666

10 5 005 5 391 5 777

20 3 120 3 342 3 564

30 2 000 2 132 2 264

40 1 317 1 397 1 477

50 888 938 988

60 613 645 677

70 432 453 474

80 310 324 338

90 228 237 246

100 170 176 182

110 128 132 136

120 98 101 104

130 77 79 81

140 60 62 64

150 48 49 50

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 143

7E5 – 143

4 Torque Wrench Specifications

NOTE

Only those torque specifications quoted in this

Section are listed her e.

Channel plate to front and rear valve body bolt......................................11 N.m

Clutch accumulator housings to valve body bolt.....................................11 N.m

Control valve body and accumulator to transmission case bolt..............11 N.m

Extension housing to transmission case bolt..........................................22 N.m

Fluid pan drain plug................................................................................20 N.m

Fluid pan to transmission case bolt........................................................11 N.m

Front valve body to channel plate bolt....................................................11 N.m

Input speed sensor to transmission case bolt.........................................11 N.m

Manual shift detent lever spring and control valve body to

transmission case bolt............................................................................11 N.m

Output speed sensor to transmission case bolt......................................11 N.m

Park pawl actuator bracket to transmission case bolt .............................22 N.m

Propeller shaft flange to output shaft nut................................................57 N.m

Torque converter seal to housing bolt ...................................................3.6 N.m

Transmission converter housing to transmission case bolt ....................22 N.m

Transmission fluid pump cover to torque converter

housing bolts (240).................................................................................11 N.m

Transmission fluid pump cover to torque converter

housing bolts (241).................................................................................22 N.m

Transmission level hole plug to case......................................................11 N.m

Transmission pressure test plug to case................................................11 N.m

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 144

7E5 – 144

5 Special Tools

Tool Number Illustration Description Tool Classification

J 5590

Bearing Installer/Remover

Used to remove outer output shaft

bearings from extension housing.

Previously released.

Unique

J 6125-1B

Slide Hammer Adapter

Used in conjunction with seal removal

tool J 23129 to remove fluid filter

seals from transmission case.

Previously released.

Unique

J 7079–2

Universal Driver Handle

Used in conjunction with J 45131–1

and J 45131–2 to remove the inner

output shaft bearing from the

extension housing.

New release.

Unique

J 8092

Universal Driver Handle

Used in conjunction with J 33832 to

install new input shaft bearing into the

fluid pump.

Used in conjunction with J 44766 to

install new torque converter seal.

Previously released.

Unique

J 8763–02

Holding Fixture and Base

Used to mount and hold transmission

assembly during unit repair

procedures. Comprises fixture J 8763-

B and bench mount J 3289-20 .

Previously released.

Unique

J 21368

Pump Body Cover Alignment Band

Used in assembly and alignment to of

the fluid pump to the torque converter

housing.

Previously released.

Unique

J 23129

Universal Seal Remover

Used in conjunction with slide

hammer J 6125–1B to remove fluid

filter seals from transmission case.

New release.

Unique

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 145

7E5 – 145

J 23327

Clutch Spring Compressor

Used to compress various clutch drum

piston springs.

Previously released.

Unique

J 29369–2

Bushing and Bearing Remover

Used in conjunction with J 45143 and

J 45124 to remove input shaft bearing

from the fluid pump.

Previously released.

Unique

J 33832

Bearing Installer

Used in conjunction with J 33832 to

install new input shaft bearing into the

fluid pump.

New release.

Unique

J 38734

Intermediate Spring Compressor

Adapter

Used in conjunction with the bolt,

washer and nut from compressor J

23327, and J 45139 to compress the

direct and reverse clutch piston

spring.

New release.

Unique

J 39068

Valve Body Guide Pins

Used in the assembly and alignment

of the valve body components as well

as installation of the valve body to the

transmission case.

New release.

Available

J 43074

Clutch Spring Compressor

Used to compress the forward and

coast clutch spring retainer to enable

snap ring removal.

New release.

Unique

J 44762

Bearing Installer

Used to install output shaft bearings

into the extension housing.

New release.

Unique

J 44764

Clutch Spring Compressor

Used in conjunction with spring

compressor J 23327 to compress

overdrive clutch piston and

intermediate clutch housing sprin gs.

Used in conjunction with J 45135 to

install the overdrive clutch housin g.

New release.

Unique

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 146

7E5 – 146

J 44765

Seal Installer

Used to install extension housing

propeller shaft flange seal.

New release.

Unique

J44766

Seal Installer

Used in conjunction with driver handle

J 8092 to install new torque converter

seal.

New release.

Unique

J 44767

Seal Installer

Used to install new manual shift shaft

seal into the transmission case.

New release.

Unique

J 45000

Seal Remover

Used to remove lipped seals.

Also released as E308 and suitable

lever bar.

New release.

Available

J 45124

Removal Bridge

Used in conjunction with J 45143 and

J 29369–2 to remove input shaft

bearing from the fluid pump.

New release.

Unique

J 45126

Snap Ring Pliers

Used for removing and installing

various snap rings with the

transmission assembly.

New release.

Unique

J 45127

Centre Support Removal Tool

Used to assist in the removal and

installation of the centre support.

New release.

Unique

J 45130–1

Seal Installer Pusher

Used in conjunction with J 45130–2 to

install new input shaft fluid seals.

New release.

Unique

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 147

7E5 – 147

J 45130–2

Seal Protector

Used in conjunction with J 45130–1 to

install new input shaft fluid seals.

New release.

Unique

J 45130–3

Seal Installer Sizer

Used to size new input shaft fluid

seals once installed.

New release.

Unique

J 45131–1

Bearing Remover

Used in conjunction with J 45131–1

and driver handle J 7079–2 to remove

the inner output shaft bearing from the

extension housing.

New release.

Unique

J 45131–2

Bearing Receiver

Used in conjunction with J 45131–and

driver handle J 7079–2 to remove the

inner output shaft bearing from the

extension housing.

New release.

Unique

J 45132

Seal Protector

Used to protect the coast clutch piston

seal when installing into clutch drum.

New release.

Unique

J 45133

Seal Protector

Used to install the direct clutch piston

into the direct and reverse clutch

housing.

New release.

Unique

J 45134

Seal Protector

Used to protect the forward clutch

piston seal when installing into clutch

drum.

New release.

Unique

J 45135

Seal Protector

Used in conjunction with J 44764 to

install the overdrive clutch housin g.

New release.

Unique

Automatic Transmission – 5L40–E – Unit Repair 7E5 – 148

7E5 – 148

J 45136

Seal Protector

Used for installing the 2nd coast

clutch piston in the centre support.

Used in conjunction with J45136 to

install the low and reverse clutch

piston into the centre support.

Used in conjunction with J 44764 to

install the overdrive clutch housin g.

New release.

Unique

J 45137

Seal Protector

Used in conjunction with J 46240

when installing the 2nd clutch piston

into the centre support.

New release.

Unique

J 45139

Compressor Plate

Used in conjunction with the bolt,

washer and nut from compressor J

23327, and J 38734 to compress the

direct and reverse clutch piston

spring.

New release.

Unique

J 45140

Seal Protector

Used in conjunction with J45136 to

install the low and reverse clutch

piston into the centre support.

New release.

Unique

J 45143

Fluid Pump Bearing Remover Plate

Used in conjunction with J 45124 and

J 29369–2 to remove input shaft

bearing from the fluid pump.

New release.

Unique

J 46239

Piston Seal Protector

Comprised of three parts – J 46239-1,

J 46239-2 and J 46239-3, to i nstall

the 2nd Coast Clutch Piston

New release.

Unique

J 46240

Piston Seal Protector

Comprised of two parts – J 46240-1

and J 46240-2, to install the 2nd

clutch piston.

Unique