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ATSG FORD 4R100 User Manual

ATSG FORD 4R100
120 pages
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INDEX
Copyright © ATSG 2003
FORD 4R100
IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................... 3
GENERAL DESCRIPTION AND OPERATION ..................................................................................... 4
COMPONENT AND SOLENOID APPLICATION CHART ................................................................... 5
"PTO" GENERAL REQUIREMENTS .................................................................................................... 6
ELECTRICAL COMPONENT DIAGNOSIS ........................................................................................... 8
FLUID REQUIREMENTS ....................................................................................................................... 12
SOLENOID PACK TESTING .................................................................................................................. 12
ABBREVIATION DESCRIPTION .......................................................................................................... 14
DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION ........................................................ 15
LINE PRESSURE TEST .......................................................................................................................... 21
NON-PTO AND PTO HYDRAULIC DIFFERENCES ........................................................................... 22
PWM AND NON-PWM OIL PUMP DIFFERENCES ........................................................................... 34
CASE CHECKBALL LOCATIONS ......................................................................................................... 38
VALVE BODY CHECKBALL LOCATIONS ........................................................................................... 39
AIR PRESSURE CHECKS ...................................................................................................................... 40
TRANSMISSION DISASSEMBLY ......................................................................................................... 41
COMPONENT REBUILD SECTION
TRANSMISSION CASE ASSEMBLY ................................................................................................ 55
FRONT AND REAR PLANETARY CARRIERS ............................................................................... 64
FORWARD CLUTCH HOUSING ...................................................................................................... 66
DIRECT CLUTCH HOUSING ........................................................................................................... 69
FORWARD, DIRECT, SUN SHELL SUB-ASSEMBLY .................................................................... 76
CENTER SUPPORT ASSEMBLY ...................................................................................................... 80
INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY ............................................................. 82
OVERDRIVE GEARSET ASSEMBLY ............................................................................................... 84
COAST CLUTCH HOUSING DIFFERENCES ................................................................................ 88
COAST CLUTCH HOUSING ASSEMBLY ........................................................................................ 90
OIL PUMP ASSEMBLY ...................................................................................................................... 94
VALVE BODY ASSEMBLY ............................................................................................................... 100
TRANSMISSION FINAL ASSEMBLY ................................................................................................. 102
MANUAL VALVE CHECK .................................................................................................................... 111
MANUAL SHIFT LEVER DIFFERENCES ........................................................................................ 112
TORQUE SPECIFICATIONS ............................................................................................................... 115
VALVE BODY BOLT CHART AND IDENTIFICATION .................................................................... 116
BOLT CHART AND IDENTIFICATION ............................................................................................. 117
SPECIAL SERVICE TOOLS ................................................................................................................. 118
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
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ATSG FORD 4R100 Specifications

General IconGeneral
BrandATSG
ModelFORD 4R100
CategoryMicrophone system
LanguageEnglish

Summary

INTRODUCTION

Transmission Overview

Provides a general overview of the Ford 4R100 transmission.

TRANSMISSION IDENTIFICATION

TRANSMISSION DESCRIPTION AND OPERATION

General Description

Details the transmission's design, components, and control system.

Shift Quadrant Indicator

Explains gear selector positions and the Overdrive Cancel Switch function.

COMPONENT AND SOLENOID APPLICATION CHART

PTO "GENERAL" REQUIREMENTS

GASOLINE ENGINE PTO OPERATION

Outlines PTO operation requirements specific to gasoline engines.

TRANSMISSION FUNCTIONS DURING PTO OPERATION

Describes how the transmission behaves when the PTO is engaged.

DIESEL ENGINE PTO OPERATION

AUXILIARY" POWERTRAIN CONTROL MODULE

Details the Auxiliary Powertrain Control Module for diesel PTO.

DIAGNOSTIC CONCERNS WITH PTO EQUIPPED VEHICLES

ELECTRICAL COMPONENT DIAGNOSIS

Covers diagnostic procedures for electrical components related to PTO operation.

DTR TESTING PROCEDURE

SOLENOID PACK TESTING PROCEDURE

4R100 FLUID REQUIREMENTS

Abbreviation Description

Diagnostic Trouble Code Chart

Shift Solenoid Application Chart

SHIFT SOLENOID TROUBLE CHART GUIDE

Provides a guide for identifying and resolving shift solenoid issues.

LINE PRESSURE TEST

"NON-PTO" AND "PTO" HYDRAULIC DIFFERENCES

VALVE BODY TO CASE SPACER PLATE

Details changes made to the valve body to case spacer plate for PTO versions.

MAIN VALVE BODY

Explains modifications to the main valve body for PTO functionality.

LOWER VALVE BODY

Describes hydraulic differences in the lower valve body for PTO models.

LOWER VALVE BODY SPACER PLATE

Covers the PTO-related changes to the lower valve body spacer plate.

"PWM" AND "NON-PWM" PUMP DIFFERENCES

PUMP ASSEMBLY

Details differences in the pump assembly for PWM and Non-PWM applications.

THE SOLENOID PACK

Explains variations in the solenoid pack for PWM and Non-PWM units.

4R100 CASE CHECKBALL LOCATIONS

4R100 VALVE BODY CHECKBALL LOCATIONS

AIR PRESSURE CHECKS

TRANSMISSION DISASSEMBLY

External Components

Steps for removing external parts of the transmission.

Bottom Pan Components

Procedure for removing bottom pan and its components.

Internal Components

Detailed steps for removing internal transmission components.

COMPONENT REBUILD

Transmission Case Assembly

Instructions for rebuilding the transmission case assembly.

Planetary Carrier Differences

Explains the distinctions between 4-pinion and 6-pinion planetary carriers.

Front And Rear Planetary Carriers

Inspection and preparation steps for planetary carriers.

FORWARD CLUTCH HOUSING

Details the disassembly and rebuild process for the forward clutch housing.

DIRECT CLUTCH HOUSING "FRONT SIDE" EXPLODED VIEW

Exploded view of the direct clutch housing's front side components.

DIRECT CLUTCH HOUSING "REAR SIDE" EXPLODED VIEW

Exploded view of the direct clutch housing's rear side components.

Forward And Direct Clutch Sub-Assemblies

Steps for assembling the forward and direct clutch sub-assemblies.

Center Support Assembly

Instructions for the proper assembly of the center support.

Intermediate/Overdrive Support Assembly

Details the rebuild procedure for the intermediate/overdrive support.

Overdrive Gearset Assembly

Steps for disassembling and assembling the overdrive gearset.

Coast Clutch Housing Changes

Explains model-specific changes to the coast clutch housing.

Coast Clutch Housing

Instructions for rebuilding the coast clutch housing.

OIL PUMP ASSEMBLY "FRONT" SIDE EXPLODED VIEW

Exploded view of the front side of the oil pump assembly.

OIL PUMP ASSEMBLY "REAR" SIDE EXPLODED VIEW

Exploded view of the rear side of the oil pump assembly.

VALVE LINE-UPS IN PUMP ASSEMBLY

Illustrates valve arrangements within the pump assembly.

Oil Pump Body And Cover Assembly

Procedure for disassembling and assembling the oil pump body and cover.

TORQUE SPECIFICATIONS

VALVE BODY BOLT CHART

BOLT CHART

SPECIAL SERVICE TOOLS

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