Keeping Ahead of an Ever-Changing Market

84 Pages·2009·27.05 MB·English

TM
FOR THE TRANSMISSION REBUILDING INDUSTRY
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48RE Torque Converters:
An Update for Longer Life
20 Steps to Successful
Transmission Repair
AUGUST 2009
11CCVVRR--880099bb..iinndddd 22 77//2211//0099 1111::1177::1155 AAMM
GRTSAD-08-09 6/26/09 1:57 PM Page 1
Sonnax Makes it Easy to Fix the Toyota Right!
2.
1.
Toyota
U151E/F, U250E
Upper
Valve Body
Lower
Valve Body
3.
4.
5.
7.
More information is available 6.
atwww.sonnax.com
PROBLEM SOLUTION
Tool Required Part Number
• Harsh lockup
• Converter apply/release complaints 1. Oversized Secondary Pressure Regulator F-57917E-TL16 57917E-16K*
• Burned converters Valve Kit & VB-FIX
• TCC apply/release problems
• Converter codes 2. Lockup Control Plunger Valve & Sleeve Kit 57917E-03K*
• Burned converters
• Harsh/flare upshifts
• TCC slip or RPM cycling 3. Solenoid Modulator Valve Kit 27741-13K
• Loss of cooler flow/overheating
• Burned B2 brake/clutch
• Delayed reverse 4. B2 Apply Control Plunger Kit 27741-06K
• Loss of engine braking in manual low
• Burned B1 brake/clutch
• 2-3 or 4-3 bind-up condition 5. B1 Apply Control Plunger Kit 27741-04K
• Harsh 1 through 4 maneuver shifts
• Insufficient line rise in drive ranges
•Higher than normal reverse pressures 6. Boost Valve Assembly 27741-01K
• Soft shifts
• Low/high line pressure
• Soft and/or harsh shifts 7. Oversized Pressure Regulator Boost Valve Kit 57917E-TL8* 27741-08K
• Clutch and band failures
*Note: These kits also fit the Toyota
U140E/F, U240E & U241E Valve Body.
Automatic Drive • P.O. Box 440 • Bellows Falls, VT 05101-0440 USA • 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com • [email protected]
©2009 Sonnax Industries, Inc.
GGEEAARRSS
TABLE OF CONTENTS
FOR THE TRANSMISSION REBUILDING INDUSTRY
AUGUST 2009
PHONE [phone] FAX [phone]
Chief Executive Officer Dennis Madden
Managing Editor Rodger Bland
48RE Torque Converters: An Mercedes 722.9 Preliminary 20 Steps to Successful
Technical Director Lance Wiggins
Update for Longer Life Information; Part 3 Transmission Repair
Advertising Frank Pasley
Page 36 Page 10 Page 24
Senior Designer Jeanette Troub
SPECIAL INTEREST & TECHNICAL
Contributing Editors Steve Bodofsky
Kit Lindsay Paul Mathewson
Thom Tschetter Charles E. (Ed) Doyle, Jr
4 GM PTO SySTeMS; ParT 2 Of 2 — by Steve Garrett
ATRA Technical Staff Bill Brayton
Mike Brown Steve Garrett 10 Mercedes 722.9 Preliminary Information; Part 3
Pete Huscher Jon Rodriguez — by Mike Souza
Randall Schroeder Dave Skora
Mike Souza 20 Precision International: Keeping ahead of
an ever-Changing Market
Director of Membership & IT Svc Kelly Hilmer
Seminars & Convention Manager Vanessa Velasquez 24 PlayInG wITh fIre: 20 Steps to Successful Transmission repair
Bookstore Manager Shaun Velasquez
— by Jon Rodriguez
30 hope and Change: a new Technique for Selling Transmission
repairs — by Kit Lindsay
The views expressed in this publication should not necessarily be interpreted as
the official policy of the Automatic Transmission Rebuilders Association (ATRA). 34 new Tires for a Clown Car — by Thom Tschetter
Publication of product information or any advertising does not imply recommenda-
36 DOCTOr DOCTOr, It Hurts When I Shift… 48re Torque Converters:
tion by ATRA.
GEARS™, a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030, an Update for longer life — by Randall Schroeder
is published for the betterment of the transmission industry and is distributed
42 Introducing your Team — by Paul Mathewson
nine times per year. No part of this issue may be reproduced without prior written
permission of the publisher. GEARS is distributed to members of the transmis- 44 6T70/6T75; The future is now Part 3 — by Steve Garrett
sion industry in the United States, Canada, ATRA Members in Mexico & Europe,
50 TrenCh rePOrTS: a Visit to Minneapolis
and related automotive industry firms and individually. Send changes of address
to GEARS in care of ATRA. Subscriptions are available by contacting GEARS — by Dennis Madden
in care of ATRA.
54 61st annual State high School Skills USa Competition
Advertisers and advertising agencies assume full liability for all content of
advertisements printed and also assume full responsibility for any claims arising — by Charles E. (Ed) Doyle, Jr
therefrom against the publisher. The publisher reserves the unqualified right to
reject any advertising copy as it deems appropriate, with or without cause. 58 aTra's Powertrain expo in las Vegas — by Dennis Madden
GEARS is designed to provide accurate and authoritative information in regard 64 MeMBerShIP MaTTerS: helping Members reach More
to the subject matter covered. It is distributed with the understanding the publisher
Customers— by Kelly Hilmer
is not engaged in rendering legal, accounting or other professional service. If legal
advice or other expert assistance, is required, the services of a competent profes-
sional person should be sought— from a Declaration of Principles jointly adopted
by a Committee of the American Bar Association and Committee of Publishers.
GEARS also welcomes articles submitted by members of the industry. DEPARTMENTS
GEARS considers all articles for publication that contribute positively to the
welfare of the transmission industry, and reserves the right to edit all articles it
publishes. If you would like to submit an article to GEARS, include background
information about the author and a telephone number where he/she may be reached.
If you want submissions returned, enclose a self-addressed, stamped envelope. 2 frOM The CeO: all you need is the Do — by Dennis Madden
65 aTra news
Editorial and Business Offices
68 Powertrain Industry news
2400 Latigo Avenue, Oxnard CA 93030
Phone [phone] 78 Shoppers and Classified
Fax [phone]
www.gearsmagazine.com 80 list of advertisers
www.atra.com
www.atraonline.com
Publications Mail agreement no. 40031403 On The Cover: Precision International:
return Undeliverable Canadian addresses to: Keeping Ahead of an Ever-Changing Market
Station a, PO Box 54, windsor, On n9a 6J5 (Paid Advertisement) Page 20
email: [email protected]
Issue #141 Printed in U.S.a. Copyright aTra 2009
FROM THE CEO
All You Need SPEAKER
by Dennis Madden
is the Do
www.atra.com
W
e first covered the Need– Ideas like this are often met with Members’ shops. It seems so obvious
Do relationship in the May some type of challenge; that they’re a now, but as an association that was
2007 issue of GEARS. The sellout or don’t hold true to the con- focused on tech for so long, it was easy
concept was a departure from what had cept of being a rebuilder. But I suggest to set the controls on autopilot and let
become a traditional business model in that a change in tactics that starts with the industry set its own path.
that it wasn’t centered on what we have the customer will ultimately result in This new direction in thinking
and then finding ways to sell it. Rather, more rebuilding, not less. In fact, we allowed us to take advantage of oppor-
the Need–Do concept requires that you learned this from our very first What’s tunities we might otherwise not even
discover the customer’s needs and then Working study back in 2006. Shops that have noticed, such as interview oppor-
find a way to fulfill them. had a business purpose centered on the tunities on automotive radio shows,
The fact is, nobody needs a trans- customer scored much higher and were advertising on Facebook, and other
mission; not even if they put the shifter more profitable than those centered ideas we’ll share as we progress.
into drive and their car won’t move. primarily on profit. Of course, we never abandoned our
Their need is generally something else technical service or stopped thinking
(such as getting the kids to school, get- It means that you about ways to improve the Golden Rule
ting to work, getting their life back on Warranty program. This new direc-
start with the
schedule), and if addressed correctly, tion simply means that we now focus
your talent as a transmission repair spe- customer’s needs and more on consumers and ways to reach
cialist (rebuilder) can be used to fulfill them, because that’s what our Members
then find solutions to
that need. need.
Need–Do doesn’t necessarily mean meet those needs. And it doesn’t mean that you, as
do whatever’s necessary to get them a transmission rebuilder, have to give
back on the road in the shortest amount Think this idea only works for up on your finely-honed rebuilding
of time. And it doesn’t mean lower- shop owners and transmission rebuild- skills. It means that you start with the
ing your standards as a transmission ers? It’ll work for any business. Earlier customer’s needs and then find solu-
rebuilder by cutting corners to compete this year I was thinking about ATRA, tions to meet those needs. Your rebuilt
with the low-baller down the street. It the What’s Working program for Expo, transmission may simply be the best
simply means that you start by identify- and our consumer study, when I asked a answer for their needs; getting them
ing the customer’s needs, and then work simple question: “What do our Members back on the road with peace of mind
to meet those needs, rather than starting need”? Seemed sort of odd to ask that that this problem is behind them. Then
with the commodity and try to figure question; we’ve been at this for so long again, you may find another solution.
out how to sell it. that you'd think the answer would be But still, it starts with the customer.
I described this idea from the cus- second nature by now. We’ll discover more ways you can
tomer’s point of view in the last issue But still I asked. I asked the ATRA meet the needs of your customers at this
with my experience getting my truck staff. I asked our Board Members. years Expo in Las Vegas. You already
smog checked. And there are examples I asked ATRA Members I visited, have everything it takes: You have the
of this popping up around us as shop and the answer was always the same: expertise… you have the desire… all
owners explore this tactic. Kit Lindsay, Customers. Our Members need cus- you Need is the Do.
an ATRA member from Warrensburg, tomers.
Missouri shares his experience as he It became clear then that one of
reconsiders how he sells his work on our main goals should be to reach
page 30 of this issue. consumers and drive them into ATRA
 GEARS August 009
As a dedicated transmission professional
Rick Basta, owner of Transmission Kings,
knows the secret to a successful shop is
dependable performance and satisfied
customers. That’s why he rebuilds with
TransTec®. “MY GUYS
No surprises. Buy a TransTec® kit and you
can bet the bank that all the parts required ALWAYS REQUEST
for the job are there and that they all fit. It’s
no accident; our engineering department,
TRANSTEC®.”
product development and technical staffs,
plus a proven QA system, combine to give
you the assurance you can’t get anywhere Rick Basta,
else. Owner of Transmission Kings
Manufactured to meet the strictest OE Cleveland, OH
standards, TransTec® kits contribute to a
faster rebuild with virtually no comebacks.
And detailed technical inserts reinforce what
the technicians learn at various seminars.
These are just a few reasons why transmis-
sion rebuilders request “the kit in the gold
and black bag”.
TransTec® kits are produced by Freuden-
berg-NOK™, the American partnership with
more than $6 billion in resources. Yet it is
the close, personal support that impresses
transmission shops like Rick’s.
TransTec® makes it easy.
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A Division of Freudenberg-NOK
New TransTec ad 9397.indd 1 4/21/08 9:47:57 AM
GM PTO Systems; Part 2 of 2
GM PTO

Systems; Par t 2 of 2
by Steve Garrett
wwwwww..aattrraa..ccoomm
Welcome back. In this seg- computer based and require the use of a correct components and programming
ment we will look a little scan tool to diagnose and recalibrate the are used:
deeper into the GM Power systems. Some applications have the See Chart 1.
Takeoff (PTO) system. potential for fast idle and PTO opera- As you may have noticed, the
GM PTO systems consist of a tion; others don’t. 2007-2008 applications aren’t included
combination of aftermarket- and OE- The application list indicates on the list. GM made major changes to
level parts and components. All of the which vehicles have PTO and fast idle the PTO system for the 07-08 applica-
GM systems since the late 1990s are capability, (figure 1) assuming all the tions. This makes upgrading a non-PTO
Figure 1
Engine Gas Engine
Application 99 00 01 02 03 04 05 06
RPO Diesel Size
Savana/Express Vans LP4,L21, L18 G 7.4L, 8.1L X X X X
Savana/Express Vans L65 D 6.5L X X
Sierra/Silverado LP4,L21, L18 G 7.4L, 8.1L X X X X X X X X
Sierra/Silverado L65, LB7 D 6.5L, 6.6L X X X X X X X X
Suburban/Yukon XL LP4, L21, L18 G 7.4L, 8.1L X X X X X X X X
Topkick/Kodiak LB7, LG5, LG4, D 6.6L, 7.2L, 7.8L X X X X X X X X
Topkick/Kodiak L18, LP4, L21 G 7.4L, 8.1L X X X X X X X X
Chart 1
4 GEARS August 2009
44ssggPPTTOO..iinndddd 44 77//2211//0099 33::3344::3300 PPMM

GM PTO Systems; Part 2 of 2
The PTOM per-
forms these functions:
• Monitors the opera-
tion of the PTO switch
• Controls the engage-
ment of the PTO relay
and PTO
• Monitors the opera-
tion of the PTO relay
via a feedback circuit
• Inputs and receives
information to and
from the BCM and
ECM. This informa-
tion is used for engine
shutdown, remote start,
and PTO operation.
• Inputs infor-
mation to the instru-
ment panel cluster
(IPC) regarding the
status of the PTO and
the requirements to
Figure 2
engage the PTO.
Upfitter Connector — An upfitter
STATIONARY PTO MOBILE PTO connector is located on the right frame
rail. This connector provides access to
Release Accelerator Disengage Cruise Control
all the remote functions for the PTO,
Release Brake Press and Release Brake including:
• PTO Enable
Reduce Engine Speed Reduce Engine Speed
• PTO Set
Shift to Park or Neutral Release Brake • PTO On
• Remote accelerator
Set Park Brake
• Remote engine shutdown
Chart 2
Body Control Module (BCM)
— The Body Control Module (BCM)
application cost-prohibitive. until the PTO engages. If the PTO is a major component in the GM PTO
GM offers the PTO package, which engages, the LED will stay lit con- system. The BCM contains the pro-
includes the updated floor pan, wir- stantly. If, after 3 seconds, the PTO fails gramming for the PTO. The BCM con-
ing, switches, PTO drive gear, upfitter to engage, the LED will go out. The trols the remote start feature for the
connector, and Power Takeoff Module Power Takeoff Module monitors the vehicle and the LED function for the
(PTOM) all under one RPO for the PTO relay feedback signal to determine PTO switch.
07-08 model years. To equip a 2007- whether the PTO has engaged. Electronic Brake Control
2008 vehicle for a PTO, GM recom- You can use the Set– or Resume+ Module (EBCM) — The Electronic
mends the customer specify RPO PTO buttons to increase or decrease the Brake Control Module (EBCM) moni-
when they order the vehicle. PTO speed in 100 RPM increments. tors the vehicle speed values and sends
Maximum PTO speed is limited to that information to the Power Takeoff
2007-2008 System (figure 2) 2100 RPM. Module via serial data.
PTO Switch — The PTO switch Turn the switch off to shut the PTO Engine Control Module (ECM)
is mounted in the cab on the right side off. The LED indicating PTO opera- — The Engine Control Module (ECM)
of the instrument panel. The switch tion will go off once the PTO relay has interfaces with the Power Takeoff
has 4 positions: Off, On, Set–, and turned off and the engine has reached Module via serial data. The ECM con-
Resume+. base idle. trols engine speed and engine shut-
To engage the PTO, turn the switch Power Takeoff Module (PTOM) down. The ECM interfaces with the
on. The Power Takeoff Module will — A new controller is used on 07-08 Body Control Module for the engine
engage the PTO relay if all the param- applications to control the operation of remote start function.
eters are met. the PTO. The Power Takeoff Module Instrument Panel Cluster (IPC)
The PTO LED mounted in the (PTOM) is located in a compartment in — The Instrument Panel Cluster (IPC)
switch will flash four times a second the right frame rail area. communicates with the Power Takeoff
6 GEARS August 2009
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GM PTO Systems; Part 2 of 2
Module. The IPC displays messages • Engine must be running. switch can be used to set the PTO
to the driver if the PTO is unable to • Vehicle speed must be less than the speed.
engage. These messages may include: maximum PTO limit speed (fac- The PTO will disengage from station-
See Chart 2. tory default 50 MPH (80 km/h). ary mode if:
Power Takeoff (PTO) Relay — • Cruise control must be turned off. • VSS signal indicates the vehicle is
The PTO relay is controlled by the • The brake pedal must be pressed, moving.
Power Takeoff Module. The Power then released, and must remain • You put the shift lever into gear.
Takeoff Module receives input from the released. • You press the remote engine shut-
PTO switch. When the operator turns • Engine speed must be less than down switch.
the switch on or off, the Power Takeoff 1800 RPM when the system is • You switch the PTO switch off.
Module will command the relay on or activated.
off after the required parameters have When the vehicle is in the sta-
Stationary Mode
been met. tionary mode, the operator will have
Transmission Control Module • Engine must be running a choice of two modes of operation:
(TCM) — The TCM provides transmis- • 0 MPH VSS preset PTO mode and variable PTO
sion temperature and gear state infor- • Park brake set mode. As with earlier GM systems, the
mation to the Power Takeoff Module. • Park or neutral gear range position preset mode can only be used when the
The Power Takeoff Module indicates • Brake pedal released vehicle is stationary.
the PTO status to the TCM. The TCM The PTO may be operated remotely in The values the Power Takeoff
changes shift points to minimize shift stationary mode. To operate the Module uses for operation are pro-
hunting during PTO operation. The PTO remotely, all of the criteria grammed into the system during pro-
TCM is also used to control TCC func- listed for the normal stationary duction. If the operator wants to change
tion during PTO stationary and mobile mode must be met. Then: the way the system functions, custom-
operation. • Press the remote PTO arming ized parameters may be entered with a
switch (position of the switch will scan tool.
PTO Operation
vary depending on the application When the PTO is operating in pre-
Like previous PTO systems, the and the upfitter). set stationary mode, the engine standby
07-08 system can operate in either • Within 5 seconds, switch the PTO speed will be about 800 RPM. Pressing
stationary or mobile mode. Each mode remote switch on. Set– or Resume+ will change the engine
will have a specific set of criteria that • The remote PTO LED will indicate RPM. Pressing the Set– will change the
must be met for the PTO to operate. PTO operation, first by flashing, preset speed to 1250 RPM; pressing the
These include: then remaining on. Resume+ button will change the preset
• Once the PTO is engaged, the speed to 1700 RPM.
Mobile Mode
remote mounted Set/Resume Variable mode can function in
8 GEARS August 2009
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